CCI Thermal Technologies FX5-SD User Manual

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Owner’s Manual

FX5 SD Series

Electric Forced Air Heaters for Hazardous Locations

ISO 9001

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

APPROVED LOCATIONS

The Electric Forced Air Heaters are cULus listed

certified for the following locations:

Class I, Divisions 1 & 2, Groups C & D;

Class II, Division 1, Groups E, F, & G;

Class II, Division 2 , Groups F & G;

Class I, Zones 1 & 2, Groups IIA & IIB; Temperature Code T3B 165˚C (329˚F)

(50 Hz & 60 Hz Models)

For details of hazardous locations with potential for

explosion, refer to the Canadian Electrical Code, Part 1,

Section 18 or National Electrical Code articles 500-516.

FX5-SD - 4803 60 - 350

KILOWATT RATING

HERTZ

PHASE

VOLTAGE

SEVERE DUTY

5th GENERATION

MODEL SERIES

MODEL CODING

WARNING!

READ ALL IMPORTANT INFORMATION NOTICES ON PAGES 2, 3 & 4.

Part No. 12212.Rev.1.02 Issue Date: January 2013 Printed in Canada

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

C US

Listed

Preventative Maintenance Grid

X X X

HEATER MAINTENANCE CHECKLIST

Photocopy

For Electric Forced Air Heaters

Heater Model: _________________________ Serial No.: ___________________________

Date of Maintenance: ___________________ Maintenance Done By: _________________

Comments: _________________________________________________________________

__________________________________________________________________________

WARNING

Disconnect heater from power supply at integral disconnect or 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.

IF INTEGRAL DISCONNECT IS BEING SERVICED, 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

this page

for reuse.

Annual

Start Up

1 Month 3 Month 12

Clean:

 Finned Tubes

Regular Service Severe Service

 Fan  Fan Guard  Motor  Louvers

Electrical

Check all terminal connections and conductors.

Inspect contactor contacts.

Check Fuses The Correct fuse rating and type

Mechanical

Check for fluid leakage

Check all enclosures The interiors of each enclosure

Check motor shaft bearing play

Remove dust using compressed air.

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 relocation.

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.

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.

X X X X

X X

Month

Annual

Start Up

1 Month 3 Month 12

X X

Month

PERIODIC (before and as required during heating season)

1. CLEAN � Finned Tubes 2. CHECK � Motor for smooth, quiet operation � Fan � Louvers for proper angle and tightness � Fan Guard � All explosion-proof covers for tightness

� Motor � Pressure relief device for signs of � Louvers 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 or drilling rigs, 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” (1.6mm) inside

enclosures. Taper threaded connections must be at least hand tight.

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

Photocopy

this page

for reuse.

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

Toll Free: 1-800-661-8529 (24 hrs)

U.S. & Canada

IMPORTANT NOTICES

WARNING

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

WARRANTY WILL BE VOID

Photocopy

this page

for reuse.

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 integral disconnect or 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. IF INTEGRAL DISCONNECT IS BEING SERVICED, 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 overtemperature 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. Use factory approved replacement parts only.

18. See applicable electrical codes for seal requirements in

field installed conduits. Factory installed conduits require no further sealing.

19. Crackling or pinging noises within the heater core

during start up may occur. This is normal.

20. Air discharge near the bottom of the heater may be

warmer than the top. This is normal.

21. If there are any questions or concerns regarding the

heater, contact the factory. Refer to the last page of this manual for details.

PRV

PRV LOCK NUT

PRESSURE RELIEF

VALVE (PRV) LABEL

INDICATOR

FIGURE 1

HEATER LOCATIONS

EXTERIOR WALL

FIGURE 2

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 Check the condition of the breaker switch and/or disconnect switch if the heater is so equipped. Measure continuity through

the disconnect by engaging the switch.

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

1.7 Check circuit breaker inside 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 Circuit breaker in control box tripped.

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

10.0 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 condition of contactor and wiring.

8.2 Check the PRV for signs of loss of uid and verify that the PRV label is not broken.

8.3 Heat exchanger needs to cool in order to engage switch to "ON" position.

8.4 Contact factory if further assistance is needed.

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

9.2 Check for loose or frayed wiring.

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

9.4 Change sensitivity of GFI.

10.1 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.

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

10.3 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 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 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.

FIGURE 4

ELECTRICAL

WARNING

Disconnect heater from power supply at integral disconnect or 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.

IF INTEGRAL DISCONNECT IS BEING SERVICED, 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 (see point 2, page 5) all pass through the 1” NPT 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 125 V minimum, c. have a minimum 2 amp capacity, and d. open on temperature rise.

FIGURE 5

3. Heater may be supplied with a factory installed built-in integral

disconnect. (See Figure 7B)

Field Wiring for Integral Disconnect:

a. Power Supply conductors and Ground conductor pass through

1"NPT opening of Disconnect Enclosure (see Figure 7B). Supply conductors to be wired to Disconnect Switch inside. Ground conductor to be wired to Ground Lug fastened to inside of Disconnect Enclosure.

b. If applicable, Remote Room Thermostat conductors pass

through 1"NPT opening (see Figure 7B) and are to be wired to

printed circuit board terminals marked “T’STAT”.

c. To reduce risk of ignition of hazardous atmospheres, conduit

runs must have a sealing fitting connected within 18 inches

(457 mm).

Factory installed conduits require no further sealing. Integral

Disconnect is sealed at factory.

4. The internal grounding terminal in the control enclosure (or in the integral disconnect enclosure when this option is provided) shall

be used as the equipment grounding means. An external bonding terminal is provided for a supplementary bonding connection where local authorities permit or require such a connection.

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

Circuit breaker load side terminals, this side for factory wiring only.

Connect supply conductors to this side of breaker.

1“ NPT opening for field wiring

Air intake

Active and spare

fuses (see parts list)

Printed circuit board’s terminal block

FIGURE 7A

Rear View of Heater

Air exits through louvers.

Fan rotation

Motor junction box

Control enclosure and cover

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

FIGURE 6

Optional factory

installed built-in

room thermostat.

Optional factory

installed built-in

disconnect.

FIGURE 8

Optional Built-in Disconnect & Field Wiring

Sealed at Factory

Switch load side terminals, this side for factory wiring only.

1" NPT

(Power Supply)

FIGURE 7B

1" NPT

(Remote Room

Thermostat

if applicable)

Terminals marked

“T’STAT”

For a 1-phase heater use these Switch terminals

Connect Supply Conductors to this side of Switch

FIGURE 9

(OPTIONAL)

FX5-SD TECHNICAL DATA FOR 50 HZ

ELECTRIC HEATERS

Temperature

Model

Wattage

Total

Current

Minimum

Circuit

Note

(CFM) (V) (kW) (W) (A) (A) (AWG) (A) °C °F

Air Flow

Voltage

Nominal

Wattage

Phase

Nameplate

Max. Motor

Current

Heater

Supply

Ampacity

Wire

Maximum

Fuse Size

FX5-SD-220150-025 400 220 2.5 1 2.7 2270 11.4 14.3 14 15 11.0 19.8 3619 FX5-SD-220150-042 400 220 4.2 1 2.7 3950 19.1 23.9 10 25 18.4 33.2 3619 FX5-SD-220150-063 700 220 6.3 1 2.7 6050 28.6 35.8 8 40 15.8 28.5 3619 FX5-SD-220150-084 700 220 8.4 1 2.7 8140 38.2 47.8 6 50 21.1 37.9 3619 FX5-SD-220150-126 * 1450 220 12.6 1 1.4 12100 57.3 71.6 2 75 15.3 27.5 3619 FX5-SD-230150-028 400 230 2.8 1 2.7 2480 12.2 15.3 12 20 12.3 22.1 3619 FX5-SD-230150-046 400 230 4.6 1 2.7 4310 20.0 25.0 10 25 20.2 36.4 3619 FX5-SD-230150-069 700 230 6.9 1 2.7 6610 30.0 37.5 8 40 17.3 31.2 3619 FX5-SD-230150-138 * 1450 230 13.8 1 1.4 13200 59.9 74.9 2 80 16.7 30.1 3619 FX5-SD-380350-025 400 380 2.5 3 0.7 2270 3.8 4.8 16 5 11.0 19.8 3619 FX5-SD-380350-042 400 380 4.2 3 0.7 3950 6.4 8.0 16 10 18.4 33.2 3619 FX5-SD-380350-063 700 380 6.3 3 0.7 6050 9.6 12.0 14 15 15.8 28.5 3619 FX5-SD-380350-084 700 380 8.4 3 0.7 8140 12.8 16.0 12 20 21.1 37.9 3619 FX5-SD-380350-125 1450 380 12.5 3 0.7 12100 19.0 23.8 10 25 15.1 27.3 3619 FX5-SD-380350-209 3000 380 20.9 3 1.0 20300 31.8 39.8 8 40 12.2 22.0 3619 FX5-SD-400350-028 400 400 2.8 3 0.7 2480 4.0 5.0 16 5 12.3 22.1 3619 FX5-SD-400350-046 400 400 4.6 3 0.7 4310 6.6 8.3 16 10 20.2 36.4 3619

FX5-SD-400350-069 700 400 6.9 3 0.7 6610 10.0 12.5 14 15 17.3 31.2 3619 FX5-SD-400350-093 700 400 9.3 3 0.7 8900 13.4 16.8 12 20 23.3 42.0 3619 FX5-SD-400350-139 1450 400 13.9 3 0.7 13200 20.1 25.1 10 30 16.8 30.3 3619

FX5-SD-400350-185 1450 400 18.5 3 0.7 17800 26.7 33.4 8 35 22.4 40.3 3619 FX5-SD-400350-231 3000 400 23.1 3 1.0 22200 33.3 41.6 8 45 13.5 24.3 3619 FX5-SD-415350-037 400 415 3.7 3 0.7 3510 5.1 6.4 16 10 16.3 29.3 3619 FX5-SD-415350-075 700 415 7.5 3 0.7 7240 10.4 13.0 14 15 18.8 33.9 3619 FX5-SD-415350-149 1450 415 14.9 3 0.7 14500 20.7 25.9 10 30 18.1 32.5 3619 FX5-SD-415350-224 3000 415 22.4 3 1.0 21800

31.2 39.0 8 40 13.1 23.6 3619 FX5-SD-440350-042 400 440 4.2 3 0.7 3950 5.5 6.9 16 10 18.4 33.2 3619 FX5-SD-440350-084 700 440 8.4 3 0.7 8140 11.0 13.8 14 15 21.1 37.9 3619 FX5-SD-440350-168 1450 440 16.8 3 0.7 16300 27.5 34.4 8 35 20.4 36.6 3619 FX5-SD-440350-210 3000 440 21.0 3 1.0 20300 27.5 34.4 8 35 12.3 22.1 3619

Rise

Contactor

C US

Part

Number

NOTES:

* Exceeds the 48 Amp Circuit Limit of NEC 424-22. DS5 not available for these units.

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 "D" to model number when adding a built-in disconnect switch

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

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

FX5-SD TECHNICAL DATA FOR 60 HZ

ELECTRIC HEATERS

Temperature

Model

Note

Voltage

(V) (kW) (W) (A) (A) (AWG) (A) °C °F

Nominal

Wattage

Phase

Nameplate

Max. Motor

Current

Heater

Wattage

Total

Current

Minimum

Circuit

Supply

Ampacity

Wire

Maximum

Fuse Size

FX5-SD-208160-030 208 3.0 1 2.7 2700 14.4 18.0 12 20 10.5 19.0 3619 FX5-SD-208160-050 208 5.0 1 2.7 4700 24.0 30.0 10 30 17.6 31.6 3619

FX5-SD-208160-075 208 7.5 1 2.7 7200 36.1 45.1 6 50 15.5 27.9 3619 FX5-SD-208160-100 * 208 10.0 1 2.7 9690 48.1 60.1 4 70 20.7 37.2 3619 FX5-SD-208360-030 208 3.0 3 1.4 2700 8.3 10.4 14 15 6.2 11.2 3619 FX5-SD-208360-050 208 5.0 3 1.4 4700 13.9 17.4 12 20 10.3 18.6 3619 FX5-SD-208360-075 208 7.5 3 1.4 7200 20.8 26.0 10 30 15.5 27.9 3619 FX5-SD-208360-100 208 10.0 3 1.4 9700 27.8 34.8 8 35 20.7 37.2 3619 FX5-SD-208360-150 208 15 3 1.4 14400 41.6 52.0 6 60 15.1 27.1 3619

FX5-SD-240160-030 240 3.0 1 2.7 2700 12.5 15.6 12 20 10.5 19.0 3619 FX5-SD-240160-050 240 5.0 1 2.7 4700 20.8 26.0 10 30 17.6 31.6 3619

FX5-SD-240160-075 240 7.5 1 2.7 7200 31.3 39.1 8 40 15.5 27.9 3619 FX5-SD-240160-100 240 10.0 1 2.7 9700 41.7 52.1 6 60 20.7 37.2 3619 FX5-SD-240160-150 * 240 15.0 1 1.4 14400 62.5 78.1 2 80 15.1 27.1 3619 FX5-SD-240360-030 240 3.0 3 1.4 2700 7.2 9.0 14 15 10.5 19.0 3619 FX5-SD-240360-050 240 5.0 3 1.4 4700 12.0 15.0 14 15 17.6 31.6 3619 FX5-SD-240360-075 240 7.5 3 1.4 7200 18.0 22.5 10 25 15.5 27.9 3619 FX5-SD-240360-100 240 10.0 3 1.4 9700 24.1 30.1 8 35 20.7 37.2 3619 FX5-SD-240360-150 240 15.0 3 1.4 14400 36.1 45.1 6 50 15.1 27.1 3619 FX5-SD-480160-030 ° 480 3.0 1 1.3 270 6.3 7.9 14 15 10.58 19.0 3619 FX5-SD-480160-050 ° 480 5.0 1 1.3 4700 10.4 13.0 14 15 17.6 31.6 3619 FX5-SD-480160-075 ° 480 7.5 1 1.3 7200 15.6 19.5 12 20 15.5 27.9 3619 FX5-SD-480160-100 ° 480 10.0 1 1.3 9100 20.8 26.0 10 30 20.7 37.2 3619

FX5-SD-480160-150 ° 480 15.0 1 1.3 14400 31.3 39.1 8 40 15.1 27.1 3619 FX5-SD-480160-200 ° 480 20.0 1 1.3 19400 41.7 52.1 6 60 20.1 36.1 3619

FX5-SD-480360-030 480 3.0 3 0.7 2700 3.6 4.5 14 15 10.5 19.0 3619 FX5-SD-480360-050 480 5.0 3 0.7 4700 6.0 7.5 14 15 17.6 31.6 3619 FX5-SD-480360-075 480

7.5 3 0.7 7200 9.0 11.3 14 15 15.5 27.9 3619 FX5-SD-480360-100 480 10.0 3 0.7 9700 12.0 15.0 14 15 20.7 37.2 3619 FX5-SD-480360-150 480 15.0 3 0.7 14400 18.0 22.5 10 25 15.1 27.1 3619 FX5-SD-480360-200 480 20.0 3 0.7 19400 24.1 30.1 8 35 20.1 36.1 3619 FX5-SD-480360-250 480 25.0 3 1.0 24200 30.1 37.6 8 40 12.2 22.0 3619 FX5-SD-480360-300 480 30.0 3 1.0 29200 36.1 45.1 6 50 14.6 26.4 3619 FX5-SD-480360-350 480 35.0 3 1.0 34200 42.1 52.6 6 60 17.1 30.7 3619 FX5-SD-600360-030 600 3.0 3 0.6 2700 2.9 3.6 14 15 10.5 19.0 3619 FX5-SD-600360-050 600 5.0 3 0.6 4700 4.8 6.0 14 15 17.6 31.6 3619 FX5-SD-600360-075 600 7.5 3 0.6 7200 7.2 9.0 14 15 15.5 27.9 3619 FX5-SD-600360-100 600 10.0 3 0.6 9700 9.6 12.0 14 15 20.7 18.1 3619 FX5-SD-600360-150 600 15.0 3 0.6 14400 14.4 18.0 12 20 15.1 27.1 3619 FX5-SD-600360-200 600 20.0 3 0.6 19400 19.2 24.0 10 25 20.1 36.1 3619 FX5-SD-600360-250 600 25.0 3 0.8 24200 24.1 30.1 8 35 25.1 45.2 3619 FX5-SD-600360-300 600 30.0 3 0.8 29200 28.9 36.1 8 40 14.6 26.4 3619

FX5-SD-600360-350 600 35.0 3 0.8 34200 33.7 42.1 8 45 17.1 30.7 3619

Rise

Part

Contactor

C US

Number

NOTES:

* Exceeds the 48 Amp Curcuit limit of NEC 424-22. DS5 not available for these units.

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 "D" to model number when adding a built-in disconnect switch

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

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

SPECIFICATIONS FOR ALL 50 HZ MODEL

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

Air Flow @ 21°C (m3/hr.) 679 1189 2463 5096

@ 70°F (CFM) 400 700 1450 3000

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

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

Motor Power (HP) 1/2 1/2 1/2 (min) (kW) 0.373 0.373 0.373

Fan Diameter (in.) 12 16 20

(mm) 305 406 508

Net without (lbs.) 140 168 201 Weight DS5 (kg) 63.5 76.2 91.2 with (lbs.) 152 180 213 DS5 (kg) 78.9 91.6 96.6

Shipping without (lbs.) 194 218 252 Weight DS5 (kg) 88 98.9 114.3

with (lbs.) 206 230 264 DS5 (kg) 93.4 104.3 119.7

Hazardous Location Rating Class I, Groups C and D; Class II, Groups E, F and G;

Temperature Code T3B [165C (329F)]

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 TEFC Arctic Duty. Permanently lubricated ball bearings.1425 RPM. Comes with mobil grease for low temperature operation.

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

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

Mounting Holes Four 9/16 in. (14.3 mm) diameter holes at top of heater

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

Primary automatic reset type, snap-action bimetal, open on temperature rise. Temperature High-Limit Rated 100,000 cycles at 15 amp, handles 0.128 amps/Secondary automatic reset type, snap-action bimetal, close on temperature rise. Rated 100,000 cycles at 15 amp, handles

0.128 amps

Breaker Switch Manual reset, thermal-magnetic trip unit. Provides short-circuit protection and thermal protection.

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

Optional Built-in Thermostat Explosion-proof.

Optional Built-in Disconnect Switch DS5 for use only on heaters with total current not exceeding 48-Amps

Lockout handle accepts 1/4” diameter padlock shackle

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

Contactor 75 amps. Rated for 500,000 mechanical operations. 120 Volts, 15VA coil

(separately fuse-protected)

Heat Transfer Fluid

Cabinet Material 14 ga. (0.075 in.) (1.90 mm) 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 in. (3.1 mm) steel

Overpressure Protection

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 expose to rain or snow.

Nominal kW 2.5 3.7 & 4.6 6.3 & 7.5 8.4 12.5 & 12.6 14.9 & 16.7 20.9 22.4

2°C to 28°C

Long life formulated propylene glycol and water

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

(36°

F to 82°F)

SPECIFICATIONS FOR ALL 60 HZ MODEL

Max. Altitude (ft.) 12,000 8,000 10,000 7,000 10,000 7,000 10,000 7,000 6,000 (m) 3,658 2,438 3,048 2,134 3,048 2,134 3,048 2,134 1,829

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

@ 70°F (CFM) 500 850 1750 3600

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

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

Motor Power (HP) 1/2 1/2 1/2

(min) (kW) 0.373 0.373 0.373

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

Net without (lbs.) 140 168 201 Weight DS5 (kg) 63.5 76.2 91.2

with (lbs.) 152 180 213 DS5 (kg) 78.9 81.6 96.6

Shipping without (lbs.) 194 218 252 Weight DS5 (kg) 88 98.9 114.3

with (lbs.) 206 230 264 DS5 (kg) 93.4 104.3 119.7

Hazardous Location Rating Class I, Groups C and D; Class II, Groups E, F and G;

Temperature Code T3B [165°C (329°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 TEFC Arctic Duty. Permanently lubricated ball bearings.1725 RPM. Comes with mobil grease for low temperature operation.

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

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

Mounting Holes Four 9/16 in. (14.3 mm) diameter holes at top of heater

Heating Elements Three long-life, low watt-density, high grade metal-sheathed elements Primary automatic reset type, snap-action bimetal, open on temperature rise. Temperature High-Limit Rated 100,000 cycles at 15 amp, handles 0.128 amps/Secondary automatic reset type, snap-action bimetal, close on temperature rise. Rated 100,000 cycles at 15 amp, handles

0.128 amps

Breaker Switch Manual reset, thermal-magnetic trip unit. Provides short-circuit protection and thermal protection.

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

Optional Built-in Thermostat Explosion-proof.

Optional Built-in Disconnect Switch DS5 for use only on heaters with total current not exceeding 48-Amps.

Lockout handle accepts 1/4” diameter padlock shackle

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

Contactor 75 amp. Rated for 500,000 mechanical operations. 120 Volts, 15VA coil

(separately fuse-protected)

Heat Transfer Fluid

Cabinet Material 14 ga. (0.075 in.) (1.90 mm) 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 in. (3.1 mm) steel

Overpressure Protection

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 expose to rain or snow

*Some units may be Class I, Div. 1, Group D and Class II, Div. 2, Groups F and G. Please check with factory for clarification.

Nominal kW 3 5 7.5 10 15 20 25 30 35

2°C to 28°C

Long life formulated propylene glycol and water

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

(36°

F to 82°F)

HEATER ASSEMBLY DIAGRAM

Optional Built-in thermostat replaces item #16

See control enclosure

assembly diagram (below)

See high-limit assembly diagram (below)

Optional built-in disconnect switch kit

CONTROL ENCLOSURE

ASSEMBLY DIAGRAM

BUS-BAR CONFIGURATION BUS-BAR CONFIGURATION BUS-BAR CONFIGURATION

ALL 1-PHASE MODELS FOR ALL 3-PHASE (EXCEPT 380 50 HERTZ) 3-PHASE 380 VOLT 50 HERTZ MODELS ONLY

HIGH LIMIT

ASSEMBLY DIAGRAM

PARTS LIST

FORCED AIR ELECTRIC HEATERS

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 or 4590 (for 12224) Coupling, Motor 15 9500 9500 3813 10389 Conduit, Motor 16 5371 5371 5371 5371 Cover, Thermostat Enclosure 17 3813 3813 3813 3813 Conduit, Control Enclosure 18 9314 9314 9315 9316 Conduit, Element Enclosure 19 9679 9679 9679 9679 Enclosure, Element 20 3510 3510 3510 3510 Cover, Element Enclosure

22 4983 4983 4983 Enclosure, Thermostat 23 11495 Thermostat, Built-in-kit 24 - - - Enclosure, Control 25 3619 Contactor, 75A 26 10556 (60HZ) 11295 (50HZ) Transformer, 50VA Multitap 27 3809 3809 3809 3809 Bracket, Printed Circuit Board 28 1876 1876 1876 1876 Terminal, 6-14 Ga. Screw Lug

29 9357 9357 9357 9357 Fuse, Buss MDQ - 1/2 Amp

30 3514 3514 3514 3514 Assembly, Printed Circuit Board 31 11960 11960 11960 11960 Cover, Control Enclosure 32 12094 12094 12094 12094 Plate, Trip Breaker Mount 33 - - - - Trip Breaker 35 9289 9289 9289 9289 Plug, 1" NPT Explosion Proof 36 - - - - High-Limit Kit (N.O.) Red Leads 37 - - - - High-Limit Kit (N.C.) White Leads 38 39 Bus-Bar, Small Curved 40 Bus-Bar, Large Curved 41 - - - - Kit, DS5 Assembly

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

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

12224 N/A 480V 1PH 60HZ

Painted: 3789

S.S.: 9112

Painted: 3785

S.S.: 9206

Painted: 3788

S.S.: 9111

Painted: 9354

S.S.: 9516

Provided with Core Kits**

Painted: 9204

S.S.: 9508

Painted: 9193

S.S.: 9194

Painted: 9201

S.S.: 9514

Painted: 9198

S.S.: 9511

Painted: 3783

S.S.: 9213

Painted: 4079

S.S.: 9505

12215

10562

12216 600V 3PH 60HZ

Painted: 3789

S.S.: 9112

Painted: 3786

S.S.: 9207

Painted: 3788

S.S.: 9111

Painted: 9355

S.S.: 9517

Please have model and serial number available

before calling

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: 3789

S.S.: 9112

Painted: 3787

S.S.: 9208

Painted: 3788

S.S.: 9111

Painted: 9356

S.S.: 9518

Panel, Bottom

Panel, Left Side

Panel, Top

Panel, Right

Panel, Fan Shroud

Fan Guard Kit

208/240V 1PH 60HZ 220V 1PH 50HZ

208/240/480V 3PH 60HZ 380/415V 3PH 50HZ

Bracket, Motor Mount Right

Channel, Motor Mount

Bracket, Motor Mount Left

Panel, Element Enclosure Guard

Bus-Bar, Straight

REPAIR & REPLACEMENT

Disconnect heater from power supply at integral disconnect or 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.

IF INTEGRAL DISCONNECT IS BEING SERVICED, 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.

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 10).

The heater core is vacuum charged and not field repairable on Ruffneck SD units. For questions of concerns regarding the replacement, please contact CCI Thermal Technologies Inc..

Heater surfaces may be hot.

MOTOR, FAN & FAN GUARD

1. Remove bolts holding the motor to the motor mount. On units with a builtin thermostat, remove the bolts on the back of the thermostat enclosure.

2. Remove conduit #1 located between moto junction box an d con trol

enclo sure b y tur ning it in t he direction illustrated (see Figure 10). Note

conduits #1 end, this end is indicated by a machined groove.

3. Remove the 2 piece fan guard assembly (see Figure 11).

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 12). 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 13). 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” (1.6mm) into enclosures. The groove on conduit #2 must not be more than 7/8” (22mm) from motor coupling (see Figure 10).

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 10).

and #2 are not interchangeable and have left hand threads on one

WARNING

CORE

Air inlet

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

Rotation

Remove

Install

Conduit #2 Conduit #1

Install

Remove

FIGURE 10

FIGURE 11

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 14).

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).

CONTACTOR

1. Loosen, but do not remove contactor mounting screws. Slide contactor off

mounting screws.

2. 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.

FIGURE 12

FUSE

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”.

1/16” to 3/16” (1.6 to 4.8mm)

HEATING ELEMENTS

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

Bolt-on cabinet panels are individually replaceable.

FIGURE 13

FIGURE 14

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

CCI Thermal Technologies FX5-SD User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual