Mosebach HX30-B Operation manual

HX30-B
HX30-G
HX30-W
30kW Heater

HX30 Heater
2
Read all instructions before using the heater
Contents
1) Components .............................................................................................................................. 3
Total Assembly ................................................................................................................................. 3
2) Specifications ............................................................................................................................... 3
a) H 30 Heater .................................................................................................................... 4
3) Receiving ...................................................................................................................................... 4
4) Safety ........................................................................................................................................... 5
a) Ground Cam ......................................................................................................................... 6
b) Power connections ............................................................................................................... 6
d) Air intakes and exhaust ports ............................................................................................... 6
e) Exhaust temperature ............................................................................................................ 7
f) Connecting and disconnecting ............................................................................................. 7
5) Operation ................................................................................................................................... 7
a) Pre-startup ............................................................................................................................ 7
b) Startup and Operation .......................................................................................................... 8
c) Shutdown ............................................................................................................................ 10
6) Troubleshooting ....................................................................................................................... 10
7) Replacing Fuses ...................................................................................................................... 12
8) Replacing Resistors ................................................................................................................ 16
9) Preventative Maintenance of the Heater ................................................................................. 17
10) Service Parts ...................................................................................................................... 18

HX30 Heater
3
IMPORTANT INSTRUCTIONS
1. Components
Total Assembly
HX30
2) Specifications
Blower 120VAC, single phase, 60Hz powered from control
Control power 120VAC, single phase, 60 Hz
Rating Continuous dut
Power factor 1.0
Load elements Each circuit is connected in delta.
The kW at each step is subject to a manufacturing tolerance of ±5%.
Switch Panel
Pull Handle
Fan Panel
Exhaust Panel
Thermocouple
Connections
Customer
Power
Connections
Figure 1c
Figure 1b Figure 1a
1
20VAC
Receptacle

HX30 Heater
Enclosure
Electro
-
staticall powder coat, Blue: PPG PCTZ50108
Touch up paint is Pantone 280-c color. Plastikote custom color universal blend.
Air inlet and outlet are covered b metal screens.
Heat is discharged horizontall .
Environmental Quantit two 120V, 850CFM fans to bring outside air into the heater.
Unit Weight 105 lbs.
Dimensions 18.2”x16.2”x27”
a) HX30 Heater
3) Receiving
WARNING! ELECTRIC SHOCK HAZARD. Electric shock can lead to severe injury or death.
If the heater has been damaged in transit, do not operate until a competent
technician inspects the unit and determines that it can be operated safely.
1) Check the equipment for obvious damage.
2) Document and report any exterior damage to the carrier immediately.
Input Voltage Volt.
Mode
kW
Steps
kW
Steps
Total
Power
Amps
480vAC, 3Ø
Resistive 480 15 15 30 36.1
240vAC, 3Ø
Resistive 240 15 15 30 72.25
208vAC, 3Ø
Resistive 240 11.25 11.25 22.5 62.5
240vAC, 1Ø
Resistive 240 10 10 20 83.3
120vAC, 1Ø
Resistive 240 2.5 2.5 5 41.7
3Ø
Customer Input
Customer
Ground
1Ø
Customer Input
Jumper
By
Customer
Customer
Ground

HX30 Heater
5
) Safety
This heater is designed for a variety of loads. Because of this, it is possible that voltages higher
that those applied can be present inside the heater and at external connections of the heater.
Work on heater internal systems should only be attempted by highly trained technicians and only
when power has been disconnected and cannot be reconnected to the unit.
IMPORTANT INSTRUCTIONS
When using electrical appliances, basic precautions should always be followed to reduce the risk
of fire, electrical shock, and injury to persons, including the following:
1) Read all instructions before using this heater.
2) This heater is hot when in use. To avoid burns, do not let bare skin touch hot
surfaces. Use handles when moving this heater. Keep combustible materials, such
as furniture, pillows, bedding, papers, clothes, and curtains at least 8 feet
(1.8 meters) from the exhaust of the heater and keep them away from the sides and
rear.
3) Extreme caution is necessary when any heater is used by or near children or invalids
and whenever the heater is left operating and unattended.
4) Always unplug heater when not in use.
5) Do not operate any heater with a damaged cord or plug or after the heater
malfunctions or has been dropped or damaged in any manner. Discard heater or
return to authorized service facility for examination and/or repair.
6) Do not use outdoors.
7) Do not use in wet or moist locations
8) This heater is not intended for use in wet indoor environments.
9) Do not run cord under carpeting. Do not cover cord with throw rugs, runners, or
similar coverings. Do not route cord under furniture or appliances. Arrange cord away
from traffic areas and where it will not be tripped over.
10) To disconnect heater, turn controls off, then remove plug from outlet.
11) Connect to properly grounded outlets only.
12) Do not insert or allow foreign objects to enter any ventilation or exhaust opening as
this may cause an electric shock or fire, or damage the heater.
13) To prevent a possible fire, do not block air intakes or exhaust in any manner. Do not
use on soft surfaces, like a bed, where openings may become blocked.
14) A heater has hot and arcing or sparking parts inside. Do not use it in areas where
gasoline, paint, or flammable liquids are used or stored.

HX30 Heater
6
15) Use this heater only as described in this manual. Any other use not recommended by
the manufacturer may cause fire, electric shock, or injury to persons.
16) Always plug heaters directly into a wall outlet/receptacle. Never use with a re-
locatable power tap (outlet/power strip).
17) This heater includes a visual alarm to warn that parts of the heater are getting
excessively hot. If the alarm light goes on, immediately turn the heater off and inspect
for any objects on or adjacent to the heater that may cause high temperatures. DO
NOT OPERATE THE HEATER WITH THE ALARM LIGHT ON.
18) SAVE THESE INSTRUCTIONS
a) Ground Cam
WARNING! ELECTRIC SHOCK HAZARD. The ground cam must be connected to earth
ground. Operating without a grounding connection could lead to injury or
death.
When the heater is in operation the ground cam must be firmly and electrically connected to earth
ground. Failure to do so could allow deadly voltage to be present on the surface of the enclosure.
The grounding connection provides a low resistance path to ground.
b) Power connections
WARNING! ELECTRIC SHOCK HAZARD. All power connections must be connected or
guarded. Failure to do so will expose operators to possible shock and the
possibility of grounding-out or shorting-out of the test power source,
c) Control Power
Use 120V type S or type SJ jacketed cord to a wall connection. Cord and service
rated to 10 AMP minimum. (see figure 2.)
d) Air intakes and exhaust ports
Caution! All air intakes and exhaust ports must be clear and fully open. This heater has
one air intake designed for proper air flow. Reducing or blocking air flow will lead to
overheating and heater failure.
High volumes of cooling air are needed to prevent load elements from overheating. By their very
nature, resistors under load convert electrical energy to heat. This heat must be removed from
the unit. The blower, intake, and exhaust ports are sized to provide the proper amount of cooling
air. Preventing or limiting air flow will allow the heater to overheat.
To increase the life of the load elements, allow the fans to run at least three minutes after the load
is removed or until exhaust air is cool.
Ground
Power
Control Power
Figure 2. Ground,
Power and Control
Power

HX30 Heater
7
No ductwork is permitted on intake or exhaust of this heater as this will cause a backpressure and
ruin the resistors.
Caution! Material can be moved by intake air or exhaust air. Failure to secure material
could cause injury to bystanders or damage to the heater.
Good air flow keeps the heater cool but can very easily move light debris such as paper,
cardboard, and dust with great velocity. Loose materials around the heater, especially near the
intake and exhaust, must be secured to prevent movement. Material on the exhaust side may be
blown into and injure a bystander. Material near the intake may be taken into the heater
damaging internal components.
e) Exhaust temperature
WARNING! FIRE AND BURN HAZARD. Keep flammable material at least 0 feet away from
the heater. A great deal of heat is expelled from the heater. Temperatures
inside the heater are sufficient to ignite flammable fumes or materials. Failure
to maintain proper housekeeping and properly securing flammable material
could lead to fire, burns, and/or injury.
Even with sufficient air flow, internal component temperature will exceed 400 °F. Exhaust air
temperature rise of 100 °F can be achieved at full power. Flammable materials must not be kept
around the heater. Heat from the heater could ignite this material.
f) Connecting and disconnecting
WARNING! BURN HAZARD. Attempting to connect or disconnect leads while heater is in
operation can lead to severe injury or death. Connecting or disconnecting
plugs and receptacles while current is flowing or voltage is present may cause
arcing. Arcing can generate a great deal of light, heat and possibility of
electrocution.
5) Operation
NOTE: Contact Mosebach Manufacturing if you are planning operations in ambient temperatures
above 115 °F.
Ambient plus heat generated by the resistor can cause electrical components to possibly
malfunction.
a) Pre-startup
1. Check housekeeping in the operational area and correct all unsafe conditions.
Failure to do this may result in debris being blown around and may cause a fire hazard.
2. Connect the heater’s ground cam-lock to a known earth ground.
3. Position heater so that air will flow freely into the intakes and out of the exhaust port.
4. All air intakes and exhaust ports must be clear of any blockages or debris.
5. Connect and place thermocouple(s)

HX30 Heater
8
• One or two thermocouples may be used
• Using one thermocouple will control heater based on the local temperature of that
thermocouple
• Using two thermocouples will control heater based on the average of the two local
temperatures of thermocouples
• When placing thermocouple(s), keep ten feet from the unit and not in direct exhaust
• When using two thermocouples, for optimal results do not place close to one another
b) Startup and Operation
1. Connect 3-phase 208-240V or 480V power to the heater via the three cam-lock power
connectors.
2. Connect external 120VAC 60hz power to the receptacle on the heater.
3. Ensure cable size is sufficient to carry the expected current. Failure to size conductors
properly will lead to conductor overheating, which will damage conductors and may pose
a fire hazard.
4. Turn the POWER switch to the desired FANS ONLY setting to turn the heater on. The
heater will automatically sense the voltage applied and will light either the 240V or 480V
light on the switch panel. Both fans will turn on. The thermostat will also turn on. The
following should be checked at this time:
Figure 3. Switch Panel

HX30 Heater
9
• Confirm that appropriate VOLTAGE light is illuminated GREEN. If voltage
indicator does not match source turn the heater OFF immediately.
• Confirm that both blowers are spinning and that the thermostat is on and
displaying a temperature on both lines (room temperature and desired
temperature).
5. Adjust temperature setting using the UP/DOWN arrows to the desired temperature on the
digital thermostat.
6. Place POWER in the desired HIGH/LOW position to engage resistors.
• Selecting the LOW setting will activate the upper fan and resistors at 15kW of
heat and a total 850 cfm of air exhausting from the heater.
• Selecting the HIGH setting will activate the upper and lower fans and resistors at
30kW of heat and a total 1700 cfm of air exhausting from the heater.
7. The heater will now generate heat until the temperature at the thermostat reaches the
desired temperature. The heater will automatically turn the heater elements on and off as
required to control to the desired temperature being sensed at the thermocouple(s).
8. Note that your heater thermostat is programmed with a 5 °F hysteresis value.
Room
Temperature
Desired
Temperature
Temperature
Controls

HX30 Heater
10
d) Shutdown
1. Place POWER switch in the FANS ONLY position.
2. Allow fans to operate at least three minutes or until exhaust air is cool before shutting
them off.
This cooling period will extend the life of your heater.
3. Turn POWER Switch to the OFF position and remove 120v control power.
4. Turn off source power and customer is to confirm prior to disconnection of power cables.
5. Put cables back into the storage box. (Not supplied by Mosebach)
6. Remove ground cam connections.
7. Move the unit to storage.
6) Troubleshooting
Thermostat/Heater Will
Not Turn On
Make sure POWER switch is in the LOW/HIGH position.
Make sure 120v control power is connected.
Ensure thermocouples are connected.
Blower will not turn on. Check for debris preventing fan from turning.
Check blower fuse. See Figure 6.
Load steps will not turn
on.
Check if OVER TEMPERATURE red light is on.
Check control fuses. See Figures 6 and 7.
Check resistor continuit . See Figure 14 and schematic.
Check resistor step fuses. See figure 8
Over temperature light.
This is an indication that the internal cabinet temperature has exceeded 150°F.
Make sure the cabinet is ventilated.
Check over temperature sensor (OTS) see figure 9.

HX30 Heater
11
OTS Open @ 150°F
FS1 10A Control Fuse
Figure 5. Line Fuses
Line Fuses

HX30 Heater
12
7) Replacing Fuses
1. Using a 7/16” socket or wrench, remove the 2 center bolts from the top lid of the heater.
(See figure 7)
2. Gently lay unit on its front by grasping the unit firmly on the handles.
3. Using a 7/16” socket or wrench, remove the 6 bolts that line the outer perimeter of the
panel shown in figure 8.
Figure 6. Thermal Switch
Figure 7
Center Bolts

HX30 Heater
13
4. Remove side bolt on both sides of the heater shown in figure 9.
Figure 8
7/16” Bolt
7/16” Bolt s

HX30 Heater
1
5. Remove the 4 bolts securing each wheel to the heater using a 7/16” socket. Keep wheel
bolts separate from panel bolts as they are unique.
6. Remove the three panel bolts shown in figure 10.
Figure 9
7/16” Bolt s

HX30 Heater
15
7. Support the switch panel by grabbing both sides of the panel with a firm grip.
8. Rotate the switch panel open away from the cable service loops.
9. Using a 7/16” socket or wrench, screw one bolt in to the top hole and one bolt into the
bottom hole as shown in Figure 11.
10. Service on fuses can then be performed.
Figure 10
7/16” Bolts

HX30 Heater
16
8) Replacing Resistors
Consult Mosebach Manufacturing Co.
7/16” Bolt
Top
Figure 11

HX30 Heater
17
9) Preventative Maintenance of the Heater
1. Do not use a power washer to clean off the exterior of the unit. It is high voltage
electrical equipment.
Component Action Frequency
Entire Unit Walk around the load bank
and inspect for :
a) Obvious Damage
b) Loose hardware
Check every use
All exterior bolts that hold the
sheet metal.
Tighten the ¼-20 hardware to
5 ft.-lbs.
Check monthly.
Resistance readings Using an ohm meter, check
each step for the correct
resistance. The reactors
should have continuity
between input and output.
These values are part of
Appendix B wiring schematic.
Check every 6 months
Electrical Components/ Wiring Check throughout the unit for
loose wires, or electrical
components that are no longer
secure to their mounting plate.
Check every 6 months
Fan Check the fan for damage that
could cause the airflow to
change such as damaged or
missing bearing, or damaged
blades.
Check Annually
Contactors Ensure contacts are opening
and closing
Check Annually

HX30 Heater
18
10) Service Parts
2 ECN 3085 - Added Single Phase Power Data BSB 4/29/2015
1 Added Detail to Operation Section 9/10/2014
0 Initial Release
Rev. Description Rev. By Date
Copyright © 2013 Mosebach Manufacturing Company
MOSEBACH MANUFACTURING COMPANY
1417 McLaughlin Run Road • Pittsburgh, PA 15241-3103 USA
T: 412.220.0237 Customer Care
F: 412-220-0236
www.mosebachresistors.com
OM-H 30-heater.doc September 10, 2014
“SAVE THESE INSTRUCTIONS”
Power Part Number
Fan BLWR-0055-0023
Resistor
Elements
RA-0055-0179
RA-0055-1754
RA-0055-1750
RA-0055-1753
Fuses 1A= AGC-1-R
90A=EC-9500-0742
Temperature
Controller EC-9500-1391