Cooper Crouse-Hinds EXH5 Series Quick start guide

WARNING! Read all important information notices on pages 3–5
ISO 9001
Part No. 11592.Rev.3.00 Issued June 2017 Printed in Canada
EXH5 Series
Installation, Parts, Service, and Maintenance Manual
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 329˚F (165˚C)
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.
C US
Listed
FX5 ‑ 480 3 60 ‑ 350 ‑ W ‑ T
Model
Series
5th Generation
Heater Voltage
208V, 240V,
480V, 600V
Phase
1, 3
Hertz
50, 60
Heater Kilowatts
Welded Core
T – XT-311 Thermostat with slim
junction box
XT-411 Thermostat with large
junction box
D – Built-in disconnect
P – Built-in pilot light
S – 3-way switch
Model Coding
H – Unit with high “off” de-energized
ambient temperatures
C – Heresite®coating
A – Stainless steel cabinet
U – Continuous fan
B – Low ambient option -58°F (-50°C)
L – Large junction box
EXH5
60
60 Hz Models only

TABLE OF CONTENTS
A. Heater Maintenance Checklist 3
A.1 Preventative Maintenance Grid .............................................................................3
A.2 Periodic................................................................................................................4
A.3 Annual..................................................................................................................4
B. Important Notices 5
C. Troubleshooting Tips 6
D. Installation 7
D.1 Mechanical ...........................................................................................................7
D.2 Electrical ..............................................................................................................9
D.3 Wiring Schematics ............................................................................................. 11
E. EXH5 Technical Data 12
E.1 60 Hz Electric Heaters ........................................................................................12
F. Specifications 14
F.1 60 Hz Models......................................................................................................14
G. Parts Assembly Diagram 16
H. Parts List 17
I. Repair & Replacement 18

A. HEATER MAINTENANCE CHECKLIST
Heater Model
Serial Number
Comments
Date of Maintenance
Maintenance Done By
WARNING
Disconnect heater from power supply at integral disconnect or fuse
box before opening enclosures or servicing heater.
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.
A.1 Preventative Maintenance Grid
Cells of the grid with check boxes inside are the minimum maintenance measures required to be performed at the
indicated time periods.
Regular Service Severe Service
To-Do Description Annual
Start Up Monthly Every 3
Months
Every 6
Months
Annual
Start Up Monthly Every 3
Months
Every 6
Months
Clean
Remove dust using compressed air. Do not spray with water
or solvents. Do not immerse in water or solvents. Clean the
following:
1. Motor
2. Louvers
3. Finned Tubes
4. Fan
5. Fan Guard
Check
1. Motor for smooth, quiet operation
2. Louvers for proper angle and tightness
3. All explosion-proof covers for tightness
4. Pressure relief device for signs of leakage. See Figure 1,
page 5 and refer to A.3 Annual, page 4 for further
instructions.
Electrical
Inspection
1. Inspect all terminal connections and conductors:*
Tighten loose connections. Replace conductors with
damaged insulation and frayed wiring.*
2. Inspect contactor contacts: If badly pitted, burned or
welded shut, replace with factory supplied contactor.*
3. Check fuses: The correct fuse rating and type are printed
on the circuit board. Always ensure a backup fuse is
available on the PCB.*
Mechanical
Inspection
1. Fluid leakage: Inspect the Pressure Release Valve (PRV)
label indicator for signs of rupture and degradation. If any
fluid leakage occurs from the heater, disconnect it from the
power supply and replace the core immediately.*
2. Enclosures: The interiors of each enclosure must be clean,
dry, and free of foreign materials.*
3. Motor shaft bearing and play: If the motor does not run
quietly and smoothly and has excessive play, replace the
motor.*
*For drilling rigs, this should be done every rig re-location.
Photocopy
this page
for reuse.
33
Heater Maintenance Checklist

Photocopy
this page
for reuse.
A.2 Periodic
• Clean
Motor
Louvers
Finned Tubes
Fan
Fan Guard
• 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, page 5 and refer to Annual,
page 4 (Fluid leakage), for further instructions.
A.3 Annual
• Mechanical Check
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
Section Repair & Replacement, page 18 for
details.
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.
Motor shaft bearing play. Replace motor if play
is excessive, or if motor does not run quietly
and smoothly. Motor bearings are permanently
lubricated.
Fan. Replace immediately if cracked or damaged.
Louvers. Screws should be tight. Louvers shall
not be fully closed or override stops.
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.
• 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, Crouse-Hinds recommends the contactor
be replaced every two years.
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.
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.
Electrical resistance on all load side legs. Reading
should be balanced (± 5%).
(before and as required during heating season)
(before heating season)
4
4
Heater Maintenance Checklist

B. IMPORTANT NOTICES
WARNING
Read and adhere to the following. Failure to do so may result
in severe or fatal injury. WARR ANT Y 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 integral
disconnect or fuse box before opening enclosures or
servicing heater. 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 (PRV) is
factory set. Do not tamper with lock nut. (See Figure 1,
page 5.)
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 Section D. Installation,
page 7 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 Section A. Heater Maintenance Checklist,
page 3 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
Section I. Repair & Replacement, page 18 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
104°F (40°C).
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 back cover of this manual
for details.
PRV
PRV Lock Nut Pressure Relief Valve (PRV)
Label Indicator
PRV Body
Figure 1
55
Heater Maintenance Checklist

C. TROUBLESHOOTING TIPS
1. 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 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.
2. 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,
page 6). If thermostat does not break continuity
replace thermostat.
3. 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 fluctuations.
4. Heat exchanger is dirty.
4.1 Clean the heat exchanger using compressed air.
5. PRV has released.
5.1 If there are signs that the PRV has released fluid,
PRV indicator is broken, blackening around the PRV
exit hole, or there are fluid stains visible on the top
louver, shut the unit down immediately.
5.2 Check for restricted air flow, bad motor, broken
thermostat or malfunctioned high limit.
6. 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 fluid 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 fluid, the heater
should operate normally.
6.3 The ambient temperature may be too low. If the
ambient temperature is very cold the top of the core
will be colder than the bottom – this is normal.
7. Unit cycles on high limit – unit turns on and turns off within
less than 5 minutes.
7.1 Check and see if the PRV has released fluid. Core
may have lost most or all of its fluid. 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. The Ground Fault Interrupter (GFI) trips on the main panel,
or heater blows fuses.
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. The fan is turning but very little air comes from the front of
the heater.
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.
6
6
Troubleshooting Tips

D. INSTALLATION
All applicable codes must be adhered to. For optimum heating, the
heater should be installed as follows:
D.1 Mechanical
1. Location
1.1 There are no obstructions that may impede the
heater’s air inlet or discharge.
1.2 The air discharge is directed into open areas and not
at occupants.
1.3 The air discharge is not directed at a thermostat.
1.4 The air discharge is directed across areas of heat
loss, such as doors and windows (see Figure 2,
page 7).
1.5 The air discharge is directed along and at a
slight angle toward exterior walls (see Figure 2,
page 7).
1.6 If equipment freeze protection is important, direct air
discharge at equipment.
1.7 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, page 7).
Heater Locations
Exterior Wall
Exterior Wall
Figure 2
2. Mounting
2.1 The heater must be permanently mounted in a level,
upright position for operation. See Figure 3, Figure 4,
and Figure 5 on page 7 and 8 for maximum
tilt angles, installation clearances, and physical
dimensions. For ease of installation, a variety of
mounting kits are available from the factory.
2.2 The mounting structure must be strong enough to:
– Support the heater’s weight (refer to Section F.
Specifications, page 14).
– Provide sufficient stiffness to prevent excessive
vibration.
– Withstand harsh situations such as transportable
installations.
Maximum Tilt (Either Direction)
0.5"
(12.7 mm)
1.0"
(25.4 mm)
Figure 3
Minimum Installation Clearances
(Must be maintained for service and air flow)
30"
(762 mm)
Cabinet height plus 2" (51 mm)
for ease of core removal
(see below)
4"
(102 mm)
72"
(1829 mm)
10"
, (254 mm)
For the maximum mounting height to
ensure warm air reaches the floor, refer to
Section F. Specifications, page 14
Obstruction
Figure 4
General Guideline for Installation and Wiring
77
Installation

Dimensional Tolerances +1/8" [+3 mm]
Unless otherwise specified.
Optional Built-in
disconnect switch
17 1/4" ±3/16"
[439 ±5 mm]
To field wiring opening
1" 1/2"
[38 mm]
max
3 7/8" ±1/4"
98.4mm ±6mm
3 9/16" ±1/8"
90.2mm ±3mm
1" NPT
(For field wiring on heaters
with integral disconnect)
E
D
22 5/8" MAX.
(575mm)
10 11/16" ±3/16"
(271 ±5mm)
3 3/4"
(95.3mm)
A
G
1 3/4" ±1/4" (44 ±6mm)
8" ±1/4"
(203 ±6mm)
Ø5/8" (Ø15.5mm)
MOUNTING HOLES
(4 PLCS)
Optional Built-In
Disconnect Switch
17 1/4" ±3/16"
439mm ±5mm
To field wiring opening
1" NPT
(For remote room
thermostat, if applicable)
1 1/2" MAX.
(38mm)
Slim Junction Box
Optional Built-In
Thermostat
1" NPT
(For remote room
thermostat, if applicable)
9 1/4" ±1/4"
[235 ±6 mm]
1" NPT
(For field wiring on heaters
without integral disconnect)
3 9/16" +1/8"
[90.2 mm +3 mm]
3 7/8" ±1/4"
98.4mm ±6mm
3 9/16" ±1/8"
90.2mm ±3mm
1" NPT
(For field wiring on heaters
with integral disconnect)
E
D
22 5/8" MAX.
(575mm)
10 11/16" ±3/16"
(271 ±5mm)
3 3/4"
(95.3mm)
A
G
1 3/4" ±1/4" (44 ±6mm)
8" ±1/4"
(203 ±6mm)
Ø5/8" (Ø15.5mm)
MOUNTING HOLES
(4 PLCS)
Optional Built-In
Disconnect Switch
17 1/4" ±3/16"
439mm ±5mm
To field wiring opening
1" NPT
(For remote room
thermostat, if applicable)
1 1/2" MAX.
(38mm)
Slim Junction Box
Optional Built-In
Thermostat
3 7/8" +1/4"
[98.4 mm +6 mm]
1" NPT
(For field wiring on heaters with
integral disconnect)
1" NPT
(For remote room
thermostat, if
applicable)
Optional Built-in
thermostat
ø5/8" [ø15.5 mm]
Mounting Hole
(4 plcs)
22 5/8"
(575 mm max.) 10 11/16"±3/16"
[271±5 mm]
8"±1/4"
[203±6 mm]
3" ±1/4" [76 ±6 mm]
3 3/4" (95.3 mm)
3 7/8" ±1/4"
98.4mm ±6mm
3 9/16" ±1/8"
90.2mm ±3mm
1" NPT
(For field wiring on heaters
with integral disconnect)
E
D
22 5/8" MAX.
(575mm)
10 11/16" ±3/16"
(271 ±5mm)
3 3/4"
(95.3mm)
A
G
1 3/4" ±1/4" (44 ±6mm)
8" ±1/4"
(203 ±6mm)
Ø5/8" (Ø15.5mm)
MOUNTING HOLES
(4 PLCS)
Optional Built-In
Disconnect Switch
17 1/4" ±3/16"
439mm ±5mm
To field wiring opening
1" NPT
(For remote room
thermostat, if applicable)
1 1/2" MAX.
(38mm)
Slim Junction Box
Optional Built-In
Thermostat
ø5/8" [ø15.5 mm]
Mounting Hole
(4 plcs)
22 5/8"
(575 mm max.)
10 11/16"±3/16"
[271±5 mm]
3 3/4" (95.3 mm)
1 3/4" ±1/4" [44 ±6 mm]
8"±1/4"
[203±6 mm]
Slim Junction Box
Optional Built-in
thermostat
Figure 5
8
8
Installation

D.2 Electrical
WARNING
Disconnect heater from power supply at integral disconnect or
fuse box before opening enclosures or servicing heater.
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.
1. General
1.1 Use only copper conductors and approved
explosion-proof wiring methods during installation.
Refer to Section E. EXH5 Technical Data, page 12
to 13 and heater data plate for conductor rating.
1.2 External overcurrent protection is required. Refer
to Section E. EXH5 Technical Data, page 12
to 13 and heater data plate for voltage, frequency
amperage, and phase. Supply voltage is to be within
10% of the data plate voltage.
1.3 The heater must be installed by qualified personnel
in strict compliance with electrical codes.
1.4 All heaters come factory prewired and ready for direct
connection to the power supply leads.
1.5 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.
2. Field Wiring
2.1 The supply conductors, ground conductor, and room
thermostat conductors (see D.3 Wiring Schematics,
page 11) all pass through the 1" NPT opening
(see Figure 6, page 9) and are to be wired into
the control enclosure (see Figure 7, page 9).
Rear View of Heater
Control enclosure
and cover
(Air exits through louvers)
1" NPT opening for field wiring Motor junction box
Air intake
Do not install conduit below heater. (See Figure 3)
Fan rotation
Figure 6
2.2 Heater may be supplied with a factory installed
built-in room thermostat (see Figure 8, page 10).
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:
– Be of an explosion-proof type
– Be rated 125V minimum
– Have a minimum 2 amp capacity
– Open on temperature rise
2.3 Heater may be supplied with a factory installed built-in
integral disconnect. (See Figure 8, page 10)
Field Wiring for Integral Disconnect:
– Power Supply conductors and Ground
conductor pass through 1" NPT opening
of Disconnect Enclosure (see Figure 8,
page 10). Supply conductors to be wired to
Disconnect Switch inside. Ground conductor
to be wired to Ground Lug fastened to inside of
Disconnect Enclosure.
– If applicable, Remote Room Thermostat
conductors pass through 1" NPT opening (see
Figure 8, page 10) and are to be wired to
printed circuit board terminals marked “T’STAT”.
– To reduce risk of ignition of hazardous
atmospheres, conduit runs must have a sealing
fitting connected within 18" (457 mm).
2.4 Factory installed conduits require no further sealing.
Integral Disconnect is sealed at factory.
– 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.
Control Enclosure & Field Wiring
Connect supply conductors
to this side of contactor.
Contactor load
side terminals, this
side for factory
wiring only.
Active and
spare fuses
(see Section
H. Parts List,
page 17)
Printed circuit board
Figure 7
99
Installation

Optional Built‑in Disconnect & Field Wiring
Sealed at factory
1" NPT
(Remote room
thermostat if
applicable)
Terminals
marked
“T’STAT”
Load side
terminals
for factory
wiring only.
1" NPT
(Power supply)
Connect supply
conductors to this
side of switch
Switch
terminals
Figure 8
Optional factory installed
built-in disconnect.
Optional factory installed built-in
room thermostat.
Figure 9
3. Final Inspection
3.1 Before application of electrical power:
– Check that all connections are secured and
comply with the applicable wiring diagram
(see Wiring Schematics, page 11) and code
requirements.
– Confirm that the power supply is compatible with
the data plate rating of the heater.
– Remove any foreign objects from the heater.
– Install all covers and verify that all enclosures are
well secured.
– Ensure that the fan rotates freely. See Figure 6,
page 9 for proper direction of fan rotation.
10
10
Installation

Note: *Primary must match heater voltage
1‑Phase
L1
L2
Optional
integral
disconnect
Elements
208/240/480V – 60 Hz
Contactor
Optional
pilot
light
Auto-reset
temperature
high-limit
(ambient air)
Auto-reset
temperature
high-limit
(Thermowell)
Optional room
thermostat
PCB
Fuse
Transformer*
PCB
Fuse
3‑Phase
3‑Way Switch and Continuous Fan Option
Optional
integral
disconnect
L1
L2
L3
Auto-reset
temperature
high-limit
(ambient air)
Optional room
thermostat
Auto-reset
temperature
high-limit
(thermowell)
Element Contactor
Optional
pilot
light
Optional 3-Way Switch
Auto A&C
Fan B Off
Transformer*
Elements
208/240/480/600V – 60 Hz
Motor Contactor
3‑Phase
Continuous Fan Option
L2
L3
L1
PCB
Fuse
Auto-reset
temperature
high-limit
(ambient air)
Auto-reset
temperature
high-limit
(thermowell)
Optional room
thermostat
Optional
integral
disconnect
Optional
pilot
light
Contactor
208/240/480/600V – 60 Hz
Elements
Transformer*
3‑Phase
208/240/480/600V – 60 Hz
L1
L2
L3 PCB
Transformer*
Auto-reset
temperature
high-limit
(ambient air)
Optional room
thermostat
Optional
integral
disconnect
Contactor
Optional
pilot
light
Auto-reset
temperature
high-limit
(Thermowell)
Elements
Fuse
1‑Phase
with Optional Pilot Light and 3‑Way Switch
L1
L2
Optional
integral
disconnect
Auto-reset
temperature
high-limit
(ambient air)
Auto-reset
temperature
high-limit
(thermowell)
Optional room
thermostat
Transformer*
Motor Contactor
Optional
pilot light
Optional 3-Way Switch
Fan B
Off
Auto A&C
Element Contactor
PCB
Fuse
L2
L3
L1
Auto-reset
temperature
high-limit
(ambient air)
Auto-reset
temperature
high-limit
(thermowell)
Optional room
thermostat
PCB
Optional 3-Way Switch
Off
Auto A&C
Fan B
Optional
pilot light
Transformer*
Motor Contactor
Optional
integral
disconnect
Elements
208/240/480/600V – 60 Hz
Element Contactor
3‑Phase
3‑Way Switch
Fuse
Elements
208/240/480V –60 Hz
D.3 Wiring Schematics
1111
Installation

E. EXH5 TECHNICAL DATA
E.1 60 Hz Electric Heaters
C US
Notes
* Exceeds the 48 amp circuit limit of NEC 424-22. DS5 not available for these units.
**480V: 1-phase units are certified for Class I, Div. 1, Group D and Class II, Div. 1
Groups F & G
1. Minimum conductor size for 86˚F (30˚C) ambient. Derate conductor for ambient
temperature. Use minimum 194˚F (90˚C) 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.
Model
Voltage
Nominal
Wattage
Phase
Max. Motor
Nameplate
Current
Heater
Wattage
Total
Current
Minimum
Circuit
Ampacity
Supply Wire
Maximum
Fuse Size
Temperature
Rise
Core Kit
Part Number
Contactor
Part
Number
VkW W A A AWG A°F °C
EXH5-208160-030
208
3.0
1
4.1 2700 18.5 23.2 10 25 19.0 10.5 12116
3619
EXH5-208160-050 5.0 4.1 4700 28.1 35.2 840 31.6 17.6 12117
EXH5-208160-075 7.5 4.1 7200 40.2 50.2 660 27. 9 15.5 12118
EXH5-208160-100* 10.0 4.1 9690 52.2 65.2 670 37. 2 20.7 12119
EXH5-208360-030 3.0
3
2.3 2700 10.6 13.3 14 15 11.2 6.2 12116
EXH5-208360-050 5.0 2.3 4700 16.2 20.2 10 25 18.6 10.3 12117
EXH5-208360-075 7.5 2.3 7200 23.1 28.9 10 30 27. 9 15.5 12118
EXH5-208360-100 10.0 2.3 9700 30.1 37. 6 840 3 7. 2 20.7 12119
EXH5-208360-150 15 2.3 14400 44.0 55.0 660 27.1 15.1 12120
EXH5-240160-030
240
3.0
1
4.1 2700 16.6 20.8 10 25 19.0 10.5 12122
EXH5-240160-050 5.0 4.1 4700 24.9 31.2 835 31.6 17.6 12123
EXH5-240160-075 7. 5 4.1 7200 35.4 44.2 845 27.9 15.5 12124
EXH5-240160 -100 10.0 4.1 9700 45.8 57. 2 660 3 7. 2 20.7 12125
EXH5-240160-150* 15.0 4.1 14400 66.6 83.3 490 27.1 15.1 12126
EXH5-240360-030 3.0
3
2.4 2700 9.6 12.0 14 15 19.0 10.5 12122
EXH5-240360-050 5.0 2.4 4700 14.4 18 .1 12 20 31.6 17.6 12123
EXH5-240360-075 7. 5 2.4 7200 20.5 25.6 10 30 27.9 15.5 12124
EXH5-240360 -100 10.0 2.4 9700 26.5 33.1 835 3 7. 2 20.7 12125
EXH5-240360 -150 15.0 2.4 14400 38.5 48.2 850 27.1 15.1 12126
12
12
EXH5 Technical Data

6. Add "P" to model number when adding a built-in pilot light.
7. Add "S" to model number when adding a 3-way switch.
8. Add "H" to model number for units with high "off" (deenergized) ambient
temperatures.
9. Add "U" to model number for units with continuous fan option.
10. Add "A" to model number for units with stainless steel cabinet.
11. Add “L” to model number for units with pilot and 3-way switch or large box option.
12. Add "B" to model number for units with low ambient option (down to -58°F or
-50°C).
Model
Voltage
Nominal
Wattage
Phase
Max. Motor
Nameplate
Current
Heater
Wattage
Total
Current
Minimum
Circuit
Ampacity
Supply Wire
Maximum
Fuse Size
Temperature
Rise
Core Kit
Part Number
Contactor
Part
Number
VkW W A A AWG A°F °C
EXH5-480160-030 **
480
3.0
1
0.8 2700 7.1 8.8 14 10 19.0 10.5 12129
3619
EXH5-480160-050 ** 5.0 0.8 4700 11.2 14.0 14 15 31.6 17.6 12130
EXH5-480160-075 ** 7.5 0.8 7200 16.4 20.5 10 25 27.9 15.5 12131
EXH5-480160-100 ** 10.0 0.8 9700 21.6 27. 0 10 30 3 7. 2 20.7 12132
EXH5-480160-150 ** 15.0 0.8 14400 32.1 4 0.1 845 27.1 15.1 12133
EXH5-480160-200 ** 20.0 0.8 19400 42.5 53.1 660 36.1 20.1 12134
EXH5-480360-030 3.0
3
1.2 2700 4.8 6.0 14 10 19.0 10.5 12129
EXH5-480360-050 5.0 1.2 4700 7. 2 9.0 14 10 31.6 17.6 12130
EXH5-480360-075 7.5 1.2 7200 10.2 12.8 14 15 27. 9 15.5 12131
EXH5-480360-100 10.0 1.2 9700 13.2 16.6 12 20 3 7. 2 20.7 12132
EXH5-480360-150 15.0 1.2 14400 19.3 24.1 10 25 27.1 15.1 12133
EXH5-480360-200 20.0 1.2 19400 25.3 31.6 835 36 .1 20.1 12134
EXH5-480360-250 25.0 1.2 24200 31.3 3 9.1 840 22.0 12.2 12135
EXH5-480360-300 30.0 1.2 29200 37. 3 46.7 850 26.4 14.6 12136
EXH5-480360-350 35.0 1.2 34200 43.3 54.2 660 30.7 17.1 12137
EXH5-600360-030
600
3.0 0.7 2700 3.6 4.5 14 10 19.0 10.5 12138
EXH5-600360-050 5.0 0.7 4700 5.5 6.9 14 10 31.6 17.6 12139
EXH5-600360-075 7.5 0.7 7200 7.9 9.9 14 15 2 7. 9 15.5 12140
EXH5-600360-100 10.0 0.7 9700 10.3 12.9 14 15 18.1 20.7 12141
EXH5-600360-150 15.0 0.7 14400 15.2 18.9 12 20 27.1 15.1 12142
EXH5-600360-200 20.0 0.7 19400 20.0 25.0 10 30 36.1 20.1 12143
EXH5-600360-250 25.0 0.7 24200 24.8 31.0 835 45.2 25.1 12144
EXH5-600360-300 30.0 0.7 29200 29.6 37.0 840 26.4 14.6 12145
EXH5-600360-350 35.0 0.7 34200 34.4 43.0 845 30.7 17.1 12146
1313
EXH5 Technical Data

Note:
*Some units may be Class I, Div. I, Group D and Class II, Div. 1, Group F & G.
Nominal kW
3 5 7.5 10 15 20 25 30 35
Maximum
Altitude
ft 12,000 8,000 10,000 7,000 10,000 7,000 10,000 7,000 6,000
m3,658 2,438 3,048 2,13 4 3,048 2,134 3,048 2,134 1,829
Air Flow
@ 70°F (CFM) 500 850 1750 3600
@ 21°C (m3/hr) 850 1444 2973 6116
Horizontal Air
Throw
ft 15 30 40 70
m4.6 9.1 12.2 21.3
Maximum
Mounting Height
(to underside)
ft 710 20
m2.1 3.0 6 .1
Minimum
Motor Power
HP 1/2
kW 0.373
Fan Diameter
in 12 16 20
mm 305 406 508
Net Weight
without
DS5
lbs 148 177 212
kg 67.1 80.2 96.2
with
DS5
lbs 160 189 224
kg 82.5 95.6 101.6
Shipping
Weight
without
DS5
lbs 202 227 263
kg 91.6 103.9 119. 3
with
DS5
lbs 214 239 275
kg 97 108.3 124.7
F. SPECIFICATIONS
F.1 60 Hz Models
C US
14
14
Specifications

1. Hazardous Location
Rating
Class I, Groups C and D; Class II, Groups E, F and G;
Temperature Code T3B [329°F (165°C)]*
2. 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
3. Motor Type Explosion-proof. Thermally protected. Permanently lubricated
ball bearings. 1725 RPM
4. Fan Aluminum blade. Steel spider and hub with 5/8" (15.875 mm) bore
5. Fan Guard Split design with close wire spacing. 1/4"
(6.3 mm) diameter probe will not enter
6. Mounting Holes Two 9/16". (14.3 mm) diameter holes at top
7. Heating Elements Three long-life, low watt-density, high grade
metal-sheathed elements
8. Temperature High‑Limit Automatic reset type, snap-action bimetal, open on temperature
rise. Rated 100,000 cycles at
10 amps, handles 0.128 amps
9. Control Circuit 120V, 0.128 amps, 15 VA. (Grounded)
10. Slim Junction Box 10.25" (230 mm) x 8.00" (180 mm) x 6.75" (172 mm)
11. Optional Built‑in
Thermostat
Explosion-proof. 36°F to 82°F (2°C to 28°C)
12. 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
13. Optional Three Way
Switch
Fan only, Off, Auto
14. Optional Pilot Light Indicates heat-on cycle
15. Control Transformer Multi-tap primary, 120V secondary, 50 VA
16. Contactor 75 amps. Rated for 1,000,000 mechanical operations. 120V, 15 VA
coil (separately fuse-protected)
17. Heat Transfer Fluid Long life formulated propylene glycol and water
18. Cabinet Material 12 ga. (0.104") (2.60 mm) steel. Epoxy coated with five-stage
pretreatment, including iron phosphate. Optional stainless steel.
19. Core Steel with integral aluminum fins, vacuum charged and
hermetically sealed
20. Conduit Material Heavy walled, 0.122" (3.1 mm) steel
21. Overpressure Protection Preset 100 psig (690 kPa) pressure relief valve, aluminum body,
no field serviceable parts
22. Operational Temperature
Limitations
-4ºF to 104ºF (-20ºC to 40ºC); for “B” units -58ºF to 104ºF (-50ºC
to 40ºC)
23. Storage Limitations -49°F to 176°F (-45°C to 80°C), short term to 248°F (120°C).
Do not immerse in water. Do not expose to rain or snow.
Specifications for 60 Hz Models
1515
Specifications

See control
enclosure
assembly
diagram
(below)
See high limit assembly
diagram (below)
Slim Control Enclosure Large Control Enclosure
31
29
30
27
25
24
36
35
26 28
34
Optional Built-in
thermostat
replaces item #16
Optional built-in
disconnect switch kit
High Limit
Bus‑Bar Configuration for
all 1‑Phase Models
Bus‑Bar Configuration
for all 3‑Phase
G. PARTS ASSEMBLY DIAGRAM
41
22
23
37
38
39
40
39
38
6
5
4
1
18
3
19
20
17
16
15
13
14
12
11
10
9
8
7
21
31
30
29
28
27
25
32
33
26
24
35
34
36
2
16
16
Parts Assembly DIagram

H. PARTS LIST
Please have model and serial number available before calling
Item Description 2.5 – 4.6 kW 6.3 – 10 kW 12.5 – 20 kW 20.9 – 35 kW
1Core **
2Panel, Bottom Painted: 12694-02
S.S.: 12694-03
Painted: 12699-02
S.S.: 12699-03
Painted: 12704-02
S.S.: 12704-03
3Panel, Left Side Painted: 12691-02
S.S.: 12691-03
Painted: 12696-02
S.S.: 12696-03
Painted: 12701-02
S.S.: 12701-03
4Louver Kit, c/w screws 4075 4076 4077
5Panel, Top Painted: 12693-02
S.S.: 12693-03
Painted: 12698-02
S.S.: 12698-03
Painted: 12703-02
S.S.: 12703-03
6Panel, Right Painted: 12692-02
S.S.: 12692-03
Pa inte d: 12697- 02
S.S.: 12697-03
Painted: 12702-02
S.S.: 12702-03
7Panel, Fan Shroud Painted: 3782
S.S.: 9212
Painted: 3783
S.S.: 9213
Painted: 3784
S.S.: 9214
8Fan Blade 4022 4023 4024 4025
9Fan Guard Kit Painted: 4078
S.S.: 9504
Painted: 4079
S.S.: 9505
Painted: 4080
S.S.: 9506
10
208/240V 1PH 60 Hz 1979 (US Motors) 10388 (Marathon)
480V 1PH 60 Hz 9896 (Baldor) N/A
208/240/480V 3PH 60 Hz 1699 (US Motors) 10387 (Marathon)
600V 3PH 60 Hz 2433 (US Motors) 10672 (Marathon)
11 Bracket, Motor Mount Right Painted: 3789
S.S.: 9112
Painted: 3789
S.S.: 9112
Painted: 3789
S.S.: 9112
12 Channel, Motor Mount Painted: 3785
S.S.: 9206
Painted: 3786
S.S.: 9207
Painted: 3787
S.S.: 9208
13 Bracket, Motor Mount Left Painted: 3788
S.S.: 9111
Painted: 3788
S.S.: 9111
Painted: 3788
S.S.: 9111
14 Coupling, Motor 3737 (US Motors) 4590 (Baldor & Marathon Motors)
15 Conduit, Motor 9500 3813 10389
16 Cover, Thermostat Enclosure 5371
17 Conduit, Control Enclosure 3813
18 Conduit, Element Enclosure 9314 9315 9316
19 Enclosure, Element 9679
20 Cover, Element Enclosure 3510
21 Panel, Element Enclosure Guard Painted: 12695-02
S.S.: 12695-03
Painted: 12700-02
S.S.: 12700-03
Painted: 12705-02
S.S.: 12705-03
22 Enclosure, Thermostat 4983
23 Thermostat, Built-in kit -
24 Enclosure, Control -
25 Contactor 3619
26 Transformer 12290 (60 Hz)
27 Bracket, Printed Circuit Board 3809
28 Terminal, 6-14 Ga. Screw Lug 1876
29 Fuse, Buss MDQ - 1/2 Amp 9357
30 Assembly, Printed Circuit Board 3514
31 Cover, Control Enclosure 1196 0
32 Bulb, Pilot Light 9279
33 Switch, Explosion-Proof 3-Way 13150
34 Thermowell, Ambient High-Limit 9267
35 High Limit, Ambient Temperature -
36 Plug, 1" NPT Explosion Proof 12169
37 Temperature High-Limit Kit -
38 Bus-Bar, Straight
Provided with Core Kits**
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, contact factory.
Forced Air Electric Heaters
1717
Parts List

I. REPAIR & REPLACEMENT
WARNING
Disconnect heater from power supply at integral disconnect or fuse
box before opening enclosures or servicing heater.
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.
1. After repairing any component:
1.1 Check that electrical connections are correct and
secure (see Figure 9, page 10).
1.2 Remove any foreign material from enclosures
1.3 Install and secure all covers
1.4 Ensure that all fasteners are tight
1.5 Remove all foreign objects from heater
1.6 Ensure air exits through louvers and fan rotates
counterclockwise when viewed from rear of heater
(see Figure 14, page 19).
The heater core is vacuum charged and not field repairable.
2. Core
For core removal:
2.1 Remove cabinet bottom and element enclosure cover.
2.2 Disconnect all wires entering element enclosure (see
Figure 10, page 18).
2.3 Slightly loosen all cabinet bolts shown in Figure 10,
page 18, to prevent the core from binding.
2.4 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,
page 18).
2.5 To return core to factory, use crate supplied with
exchange core to protect the element terminals and
plate threads.
2.6 To reinstall, lift the core up into cabinet while an
assistant guides the element wires into the element
enclosure conduit.
2.7 Position the core and tighten the 3 core mounting
bolts. Tighten the remaining cabinet bolts.
Loosen bolts only, do
not remove.
Element Enclosure
Remove this core
mounting bolt &
two others on the
opposite side.
Control
Enclosure
Control Enclosure
Conduit
Figure 10
3. Temperature High Limit
3.1 Remove temperature high-limit assembly and
clean the inside of the thermowell (see Figure 12,
page 18). A clean thermowell will ensure good
thermal contact.
3.2 Use only a factory supplied temperature high-limit
to ensure safe operation. (Refer to the instructions
that accompany the replacement Temperature High
Limit Kit).
3.3 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, page 18).
Figure 11
Figure 12
Figure 13
18
18
Repair and Replacement

Conduit #1
Front View
Remove
Install
Air inlet
Conduit #2
From grove to face of
coupling: 7/8" (22 mm)
Fan rotation
Remove
Install
Side View
Figure 14
Figure 15
Figure 16
4. Motor, Fan, & Fan Guard
4.1 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.
4.2 Remove conduit #1 located between motor junction
box and control enclosure by turning it in the
direction illustrated (see Figure 14, page 19). Note
that conduits #1 and #2 are not interchangeable and
have left hand threads on one end, this end is indicated
by a machined groove.
4.3 Remove the two-piece fan guard assembly (see
Figure 15, page 19).
4.4 Lift the motor assembly off the motor mount.
4.5 Before removing the fan, measure and record the
location of the fan hub on the motor shaft (see
Figure 16, page 19). If difficult to remove, use a
gear puller on the fan hub.
4.6 To reassemble, place motor assembly onto motor
mount and fasten the fan guard to cabinet.
4.7 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 17, page 20). Adjust conduit #2
to center the fan in the shroud.
4.8 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, page 19).
4.9 Bolt motor to motor mount. Manually spin the fan
blade to ensure fan rotates freely.
4.10 Air must exit through louvers and fan must rotate
counterclockwise when viewed from rear of heater
(see Figure 14, page 19).
5. Heating Elements
5.1 Heating elements are an integral part of the vacuum
charged core. A factory exchange core can be shipped
immediately from stock. Refer to 2. Core, page 18
for details.
6. Contactor
6.1 Loosen, but do not remove contactor mounting
screws. Slide contactor off mounting screws.
6.2 Replace with a factory supplied contactor of the same
rating.
7. Transformer
7.1 Replace with a factory supplied transformer of the
same rating.
7. 2 On the new transformer, select primary wires to
match heater voltage.
7.3 Ensure that the correct transformer secondary lead
is grounded (see Figure 9, page 10). Individually
terminate all unused wires using closed end
connectors.
1919
Repair and Replacement

1/16" to 3/16"(1.6 to
4.8 mm)
Figure 17
Figure 18
8. Printed Circuit Board
8.1 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 9, page 10).
8.2 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 18, page 20).
9. Fuse
9.1 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”.
10. Cabinet panels
10.1 Bolt-on cabinet panels are individually replaceable.
20
20
Repair and Replacement