Electro Industries ELECTRO DUCT User manual

12/20/2017 EI505
INSTALLATION MANUAL, PLENUM
Size
C=Plenum
EM-DI ** *5 * 16W x 16D
kW Stages
10 = 9.6 kW 2 = 2
15 = 14.4 kW 3 = 3
20 = 19.2 kW
INTENDED USE – This product is approved and label certified for water source heat pumps or
air handlers at the blower discharge, upflow only.
Drawings: EH503
ES501
XX017

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APPLICATION
This model series contains the starter plenum, its primary application is Econar manufactured
water source heat pumps. However, it can easily be adapted to other manufacturers
(ClimateMaster, etc.) having a 16 x 16 starting collar.
Electro Industries also has insert models (without starter plenum) primarily intended for
Command-Aire or other water source heat pump brands. Contact factory for assistance.
For information, all units are rated at 24Ø volts AC. When operating at lower source voltage,
the output may be reduced.
Example: 9.6KW unit, assuming normal element tolerances
220 volt source - 8KW
208 volt source - 7.3KW
NOTE: The maximum inlet air temperature is 100° F. For inlet temperatures greater than
100°, contact the factory for special assistance.
NOTICE TO HOMEOWNER AND INSTALLER
Hi-limit cycling two to ten minutes after initial turn on usually means improper deflector, baffle
installation, or insufficient airflow - carefully study and follow mechanical installations.
INSTALLATION REQUIREMENTS
1. All installation work must be performed by trained, qualified contractors or technicians.
Electro Industries, Inc., sponsors installation and service schools to assist the installer.
2. All electrical wiring must be in accordance with National Electric Code and local electric
codes, ordinances, and regulations.
3. Observe electric polarity and wiring colors. Failure to observe could cause electric shock
and/or damage to the equipment.
4. This unit can only be used for its intended design as described in this manual. Any internal
wiring changes, modifications to the circuit board, modifications or bypass of any controls, or
installation practices not according to the details of this manual will void the product
warranty, the ARL certification label, and manufacturer product liability. Electro Industries,
Inc., cannot be held responsible for field modifications, incorrect installation, and conditions
which may bypass or compromise the built-in safety features and controls.

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SPECIFICATIONS - TABLE 1
NOMINAL MIN. ELEMENT SOURCE INTERNAL SHIP
MODEL KW CURRENT+ CFM* CROSS SECTION CB FUSE WEIGHT
EM-DI1025C 9.6 40 1000 8 W x 16 D 50 N/A 15
EM-DI1535C 14.4 60 1500 8 W x 16 D 75 30 & 50 19
EM-DI2035C 19.2 80 2000 8 W x 16 D 100 50 & 50 21
* Assumes 100F inlet and all air passes through element rack. If duct/plenum is larger than element rack (without
factory deflector kit), the air volume external
(passing around) to the element rack must be added to this CFM requirement.
+ At 240 volt, single phase.
FUNCTIONAL DESCRIPTION
Refer to drawing ES5Ø1 and the symbol definitions.
Thermostat Connections - The following descriptions begin at the 24 volt control points. These
are the left lettered terminals on drawing ES5Ø1 shown as square dots.
C - Common, must be tied to 24 volt system common.
W1 - First stage heat, first 5KW section (10KW if "X" jumper is in place).
X - Second 5KW stage, factory jumpered to the "W1" terminal. Typically the "W1" function
controls the first 10KW. An outdoor stat (ODT) can be electrically installed in place of
the "X" to "W1" jumper to keep 5KW off during warmer outside temperatures.
W2 - Second stage heat, 5KW for 15KW model or 10KW for 20KW model.
O - Tie point only for wiring from room stat, no internal connection.
Y2 - Tie point only for wiring room stat compressor wire, basically no internal connection.
R - 24 volt high side, not required for normal functions, can be used as thermostat wire tie
point. Required if the room stat or air handler does not have internal blower "on"
function.
NOTE: This Electro-Duct blower turn on function cannot operate the air handler blower
relay without 24 volts at "R".
G - Air handler blower relay control voltage.
F - Room stat blower input wire, typically tied to room stat "G" terminal.

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Heater Turn-On Action - The external application of 24 volts AC between "W1" and "C"
pulls K2 relay which acts as a switch for the top 4.6KW element (E1). The red LED next to the
"W1" terminal illuminates. A signal is also diode coupled to K1 and yellow LED illuminates. K1
provides an electrical path between "R" and "G" to operate the air handler blower relay.
With external 24 volt AC between "X" and/or "W2", the same basic action follows switching on
elements E2 and E3. However, these two stages or elements contain an electronic delay of
approximately 10 seconds before K2 and/or K3 pull in. The LED opposite the appropriate terminal
indicates the control system has the appropriate element switch relay closed.
First Level Hi-Limit - The upper off-set hi-limit is connected to the two tab terminals shown on
diagram ES5Ø1 bottom left. If this limit opens due to low airflow, the top PC board red LED is
illuminated and K2, K3, and K4 relays open disconnecting all element power. This is an automatic
reset hi-limit which means it will again close (top LED off) re-establishing the element power. If this
is a cycling function, damage will result to the element relay contacts and/or elements themselves.
Second Level Hi-Limit - The hi-limits in the current carrying leg (between fuse and element) is a
dual function device. The automatic reset internal limit is set 50 below the fuse link internal
function. In other words, if the automatic reset contacts weld, the one time (permanent open circuit)
fuse link will prevent element overheating.
AUX 10 Pin Connector - For special OEM applications and for other plug-in optional devices, the
10 pin connector is represented by the various numbered terminals on the schematic diagram.
19.2KW Model - This is an added element to the 15KW shown. The fourth element has its
own relay tied directly across E3 element power. Whenever K4 switches on the E3 element, the
E4 follows immediately. The 30 amp fuse is changed to a 50 amp fuse.

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MECHANICAL INSTALLATION
The heat pump manufacturer's starter collar should be centered over the discharge blower.
Generally the blower shaft is 9Øto the facing front of this Electro-Duct. In other words, if you
would be viewing the blower motor shaft, you would see the side of the electrical control box.
Also blower centering means, the approximate 3 inch opening of the blower discharge is
centered under the electric elements. It does not mean the complete blower housing discharge is
centered, only the actual blower discharge opening itself.
In the case of the Econar unit, the Electro-Duct right side extended lip (facing Electro-Duct
control box), simply lapse on the right side of the Econar cabinet and the Electro-Duct center
side hole alignment with Econar cabinet center side screw.
ELECTRICAL HOOKUP
1. 240 VOLT SOURCE - Locate correct model number and KW size in Table 1 to determine
operating current and minimum source circuit breaker size. According to local codes,
building type, wiring run distance, etc., use the appropriate electric conductor size to
bring over the 240 volt source power. Connect to fuse block/input terminals (10KW is
terminal block only).
2. GROUNDING - Route and install the appropriate size ground conductor between the ground
lug labeled "GROUND" and building service entrance panel ground buss. This must be a
conductor sized according to the total amp rating of the appropriate model. Conduit is
not a adequate ground conductor.
3. THERMOSTAT CONTROL - See drawing EH5Ø3 and previous Functional Description
section for basic hookup:
A. Outdoor stat is not required, factory jumper is provided between "W1" and "X".
B. "W2" is not available on 10KW models.
C. 10KW model can be operated from a two stage room stat ("W1" and "X"). Remove
jumper between "W1" and "X", connect stat "W1" to "W1" and "W2" to "X".

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OPERATIONAL MONITOR LIGHTS
Green - 24 volt at "R", reference to "C".
Amber - Internal blower relay is pulled based upon an input
on either "W1", "X", or "W2".
Red (opposite stat terminal) - 24 volts (reference to "C") is at the terminal next to the red
light.
Top Red Light - First level hi-limit is open, overheat condition, insufficient airflow, dirty
filter, etc.
CFM CALCULATIONS
By measuring the temperature rise across this Electro-Duct (at a point high enough for proper
air mixing) the actual CFM can be quite easily determined. If you are having difficulties
sustaining hi-limit operation (clicking noise/top red LED) it may be a good idea to calculate the
CFM according to the formula shown at the top of the next page. To arrive at a stable outlet
temperature, you can turn off the source power and remove the smallest fuse. This will allow
you to verify or calculate the CFM without reaching the hi-limit cycling. The full amount of
elements are not required to use this formula. The accuracy of this formula will depend upon the
ability to measure the outlet air at a properly mixed and uniform spot and the accuracy of both
the clamp on amp meter (AC voltmeter).
CFM = volts x amps x 3.4
temp. rise x 1.1
REPLACEMENT PARTS
Part Number
- PC Module, 2 stage DI66Ø5
- PC Module, 3 stage DI66Ø6
- Element, 4.8KW EII# Ø6615
- First hi-limit, 135F EII# Ø5636
- Dual hi-limit EII# Ø663Ø
- Fuse - 5ØA EII# Ø664Ø
- Fuse - 3ØA EII# Ø5141

Page 1 of 2 XX017
Electro Industries, Inc.
Limited Product Warranty
Effective February 5, 2009
Electro Industries, Inc. warrants to the original owner, at the original installation site, for a period
of two (2) years from date of installation, that the product and product parts manufactured by
Electro Industries are free from manufacturing defects in materials and workmanship, when
used under normal conditions and when such product has not been modified or changed in any
manner after leaving the plant of Electro Industries. If any product or product parts
manufactured by Electro Industries are found to have manufacturing defects in materials or
workmanship, such will be repaired or replaced by Electro Industries. Electro Industries shall
have the opportunity to directly, or through its authorized representative, examine and inspect
the alleged defective product or product parts. Electro Industries may request that the materials
be returned to Electro Industries at the owner’s expense for factory inspection. The
determination as to whether product or product parts shall be repaired, or in the alternative
replaced, shall be made by Electro Industries or its authorized representative. Electro Industries
will cover reasonable labor costs to repair defective product or product parts for ninety (90) days
after installation.
TWENTY YEAR (20) LIMITED WARRANTY ON BOILER ELEMENTS AND VESSELS
Electro Industries, Inc. warrants that the boiler elements and vessels of its products are free
from defects in materials and workmanship through the twentieth year following date of
installation. If any boiler elements or vessels are found to have a manufacturing defect in
materials or workmanship, Electro Industries will replace them.
TWENTY YEAR (20) LIMITED WARRANTY ON SPIN FIN ELEMENTS
Electro Industries, Inc. warrants that the spin fin elements of its products are free from defects in
materials and workmanship through the twentieth year following date of installation. If any spin
fin elements are found to have a manufacturing defect in materials or workmanship, Electro
Industries will replace them.
FIVE YEAR (5) LIMITED WARRANTY ON OPEN WIRE ELEMENTS
Electro Industries, Inc. warrants that the open wire elements of its products are free from
defects in materials and workmanship through the fifth year following date of installation. If any
open wire elements are found to have a manufacturing defect in materials or workmanship,
Electro Industries will replace them.

Page 2 of 2 XX017
THESE WARRANTIES DO NOT COVER:
1. Costs for labor for removal and reinstallation of an alleged defective product or product parts,
transportation to Electro Industries, and any other materials necessary to perform the exchange,
except as stated in this warranty. Replacement material will be invoiced to the distributor in the usual
manner and will be subject to adjustment upon verification of defect.
2. Any product that has been damaged as a result of being improperly serviced or operated, including,
but not limited to, the following: operated with insufficient water or airflow, allowed to freeze,
subjected to flood conditions, subjected to improper voltages or power supplies, operated with airflow
or water conditions and/or fuels or additives which cause unusual deposits or corrosion in or on the
product, chemical or galvanic erosion, improper maintenance or subject to any other abuse or
negligence.
3. Any product that has been damaged as a result of natural disasters, including, but not limited to, the
following: lightning, fire, earthquake, hurricanes, tornadoes or floods.
4. Any product that has been damaged as a result of shipment or handling by the freight carrier. It is the
receiver’s responsibility to claim and process freight damage with the carrier.
5. Any product that has been defaced, abused, or suffered unusual wear and tear as determined by
Electro Industries or its authorized representative.
6. Workmanship of any installer of the product. This warranty does not assume any liability of any
nature for unsatisfactory performance caused by improper installation.
7. Transportation charges for any replacement part or component, service calls, normal maintenance;
replacement of fuses, filters, refrigerant, etc.
CONDITIONS AND LIMITATIONS:
1. If at the time of a request for service the original owner cannot provide an original sales receipt or a
warranty card registration then the warranty period for the product will have deemed to begin thirty
(30) days after the date of manufacture and NOT the date of installation.
2. The product must have been sold and installed by a licensed electrical contractor, a licensed
plumbing contractor, or a licensed heating contractor.
3. The application and installation of the product must be in compliance with Electro Industries’
specifications as stated in the installation and instruction manual, and all state and federal codes and
statutes. If not, the warranty will be null and void.
4. The purchaser shall have maintained the product in accordance with the manual that accompanies
the unit. Annually, a qualified and licensed contractor must inspect the product to assure it is in
proper working condition.
5. All related heating components must be maintained in good operating condition.
6. All lines must be checked to confirm that all condensation drains properly from the unit.
7. Replacement of a product or product part under this limited warranty does not extend the warranty
term or period.
8. Replacement product parts are warranted to be free from defects in material and workmanship for
ninety (90) days from the date of installation. All exclusions, conditions, and limitations expressed in
this warranty apply.
9. Before warranty claims will be honored, Electro Industries shall have the opportunity to directly, or
through its authorized representative, examine and inspect the alleged defective product or product
parts. Remedies under this warranty are limited to repairing or replacing alleged defective product or
product parts. The decision whether to repair or, in the alternative replace, products or product parts
shall be made by Electro Industries or its authorized representative.
THESE WARRANTIES DO NOT EXTEND TO ANYONE EXCEPT THE ORIGINAL PURCHASER AT RETAIL AND ONLY WHEN THE PRODUCT IS IN THE ORIGINAL
INSTALLATION SITE. THE REMEDIES SET FORTH HEREIN ARE EXCLUSIVE.
ALL IMPLIED WARRANTIES, INCLUDING WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED WITH
RESPECT TO ALL PURCHASERS OR OWNERS. ELECTRO INDUSTRIES, INC. IS NOT BOUND BY PROMISES MADE BY OTHERS BEYOND THE TERMS OF THESE
WARRANTIES. FAILURE TO RETURN THE WARRANTY CARD SHALL HAVE NO EFFECT ON THE DISCLAIMER OF THESE IMPLIED WARRANTIES.
ALL EXPRESS WARRANTIES SHALL BE LIMITED TO THE DURATION OF THIS EXPRESS LIMITED WARRANTIES SET FORTH HEREIN AND EXCLUDE ANY
LIABILITY FOR CONSEQUENTIAL OR INCIDENTAL DAMAGES RESULTING FROM THE BREACH THEREOF. SOME STATES DO NOT ALLOW THE EXCLUSION OR
LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATIONS OR EXCLUSIONS MAY NOT APPLY. PRODUCTS OR PARTS OF
OTHER MANUFACTURERS ATTACHED ARE SPECIFICALLY EXCLUDED FROM THE WARRANTY.
THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY HAVE OTHER RIGHTS WHICH VARY UNDER THE LAWS OF EACH STATE. IF ANY
PROVISION OF THIS WARRANTY IS PROHIBITED OR INVALID UNDER APPLICABLE STATE LAW, THAT PROVISION SHALL BE INEFFECTIVE TO THE EXTENT OF
THE PROHIBITION OR INVALIDITY WITHOUT INVALIDATING THE REMAINDER OF THE AFFECTED PROVISION OR THE OTHER PROVISIONS OF THIS WARRANTY.