Ruffneck XL4 Vacucore Series User manual

Owner’s Manual
XL4 Vacucore Series
Electric Forced Air Heaters for Hazardous Locations
This manual covers the installation, maintenance, repair and replacement parts.
APPROVED LOCATIONS
RUFFNECK FX4-Series Explosion-Proof Electric Air Heaters are
UL listed for use in hazardous locations;
Class I, Division 1&2, Group D;
Class II, Division. I, Group E, F, &G;
Class II, Division 2 , Group F&G.
For details of hazardous environments with potential for e
WARNING!
READ ALL IMPORTANT NOTICES ON PAGE 3.
CERTIFIED Part No. 6702-1 Printed in Canada
Thermon Heating Systems, Inc.
Ruffneck and VacuCore are registered trademarks. Copyright©2000. All rights reserved.
LISTED
®
MODEL CODING
XL 4 20 - 480 3 60 - 35
KILOWATT RATING
HERTZ
PHASE
VOLTAGE
FAN SIZE (INCHES)
4th GENERATION
MODEL SERIES
APPROVED LOCATIONS
RUFFNECK XL4 VacuCore®Series Electric Air Heaters are
CSA certified or UL listed for the following locations:
Class I, Divisions 1 & 2, Group D;
Class II, Division 1, Groups E, F, & G;
Class II, Division 2 , Groups F & G;
Class I, Zones 1 & 2, Group IIA
Temperature Code T3B 165˚C (329˚F);
(50 Hz & 60 Hz Models)
or
Class I, Divisions 1 & 2, Groups C & D;
Class II, Divisions 1 & 2, Groups F & G;
Class I, Zones 1 & 2, Groups IIA & IIB
Temperature Code T3B 165˚C (329˚F);
(60 Hz Models Only)
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.
TM
¸

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HEATER MAINTENANCE CHECKLIST
For Electric Forced Air Heaters
Heater Model: _____________________________ Serial No.: _______________________________
Date of Maintenance:_______________________ Maintenance Done By: ____________________
Comments: _________________________________________________________________________
__________________________________________________________________________________
WARNING
Disconnect heater from the power supply before opening enclosures or servicing heater.
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.
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
❑Louvers
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.
❑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%).
2. MECHANICAL
❑Check for fluid leakage. The heater core is vacuum charged and contains ethylene glycol which is poisonous. 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
U.S. & Canada

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FIGURE 1
EXTERIOR WALL
WALL
EXTERIOR
HEATER LOCATIONS
HEATER LOCATIONS
EXTERIOR WALL
EXTERIOR
WALL
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. Before opening any enclosures, disconnect the heater
from the power supply. 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. Operate the heater only while it is permanently
mounted in an upright position. Refer to the
“Installation - Mechanical” section for details.
11. 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.
12. The heater core is vacuum charged and contains
ethylene glycol which is poisonous. 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.
13. Do not operate the heater with any of the louvers fully
closed or overriding their stops.
14. Do not operate the heater in atmospheres corrosive to
steel or aluminum.
15. Do not operate heater in ambient termperatures above
40°C (104°F).
16. Use factory approved replacement parts only.
17. See applicable electrical codes for seal requirements in
field installed conduits. Factory installed conduits
require no further sealing.
18. Crackling or pinging noises within the heater core
during start up may occur. This is normal.
19. Air discharge near the bottom of the heater may be
warmer than the top. This is normal.
20. If there are any questions or concerns regarding the
heater, contact the factory. Refer to the last page of
this manual for details.
WARRANTY WILL BE VOID
IF INSTRUCTIONS ARE NOT FOLLOWED
IMPORTANT NOTICES
WARNING
Read and adhere to the following. Failure to do so may result in severe or fatal injury.
WARRANTY WILL BE VOID
INSTALLATION
The installation instructions provide a general guideline for the installation and wiring of the heater.
All applicable codes must be adhered to.
MECHANICAL
L O C A T I O N
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 1).
5. The air discharge is directed along and at a slight angle
toward exterior walls (see Figure 1).
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 1).

MOUNTING
1. The heater must be permanently mounted in a level,
upright position for operation. See Figures 2, 3, and 4
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 abusive situations such as
transportable installations.
ELECTRICAL
WARNING
Disconnect the power supply before installation of the heater. 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 applicable codes.
GENERAL
1. Use only copper conductors and approved explosion-proof means of wiring to make connections to the heater. 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, amperage,
and phase. Supply voltage is to be within 10% of the data plate voltage.
FIELD WIRING
1. Supply conductors, ground conductor, and room thermostat conductors (see note 2 below) pass through the 1”NPT opening
(see Figure 5) and are to be wired into the control enclosure (see Figure 6).
(EITHER DIRECTION)
MAXIMUM TILT ANGLES
(25.4mm)
(12.7mm)
1/ 2 " 1"
10"
72"
30"
2 in.(51mm) for ease
(254mm) (1829mm)
(762mm)
of core removal
For the maximum mounting height
to ensure warm air reaches the floor,
Cabinet height plus
refer to the "SPECIFICATIONS" section.
OBSTRUCTION
Clearance is not
required at the top.
(see Figure 4).
(102mm)
4"
FLOOR
MINIMUM INSTALLATION CLEARANCES
(MUST BE MAINTAINED FOR SERVICE AND AIR FLOW)
- 4 -
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.
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 5) and are to
be wired into the control enclosure (see Figure 6).
(continued next page)
FIGURE 2
FIGURE 3
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
(Either direction)
(MUST BE MAINTAINED FOR SERVICE AND AIR FLOW)
Mounting hole
(2 places)
Dimensional tolerances
For the maximum mounting height to
ensure warm air reaches the floor, refer to
the “SPECIFICATIONS” section.
22-5/8” (575mm)
MAX
15-1/16’’
(399mm)

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FIGURE 7
FIGURE 6
FIGURE 5
Fan
rotation
1“ NPT opening
for field wiring
Rear View of Heater
Air
intake
Motor
junction box
Optional factory
installed built-in
room thermostat.
Connect supply conductors
to this side of contactor.
For a 1-phase
heater, use these
contactor lugs.
Contactor load
side terminals,
this side for
factory wiring
only. Active and spare fuses
(see parts list)
Printed circuit board’s
terminal block
Grounding lug
Control enclosure
and cover
Do not install conduit below heater (see Figure 3).
Control Enclosure & Field Wiring
Air exits through
louvers.
WIRING DIAGRAMS
All 1 - Phase
FIGURE 8
3 - Phase 50Hz 415 Volt
3 - Phase 60 Hz except 600 Volt Groups C & IIB
3 - Phase 50Hz 380 Volt
3 - Phase 600Hz Volt Groups C & IIB

REPAIR & REPLACEMENT
WARNING
Disconnect power supply before opening enclosures or
servicing heater. Lock the switch in the “OFF” (open)
position and/or tag the switch to prevent unexpected
power application. Heater surfaces may be hot.
1. After repairing any component:
a. check that electrical connections are correct and
secure (see Figure 8),
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 13).
C O R E
The heater core is vacuum charged and not field
repairable. For core removal:
1. Remove cabinet bottom and element enclosure cover.
2. Disconnect all wires entering element enclosure (see
Figure 9).
3. Slightly loosen all cabinet bolts shown in Figure 9, to
prevent the core from binding.
4. With an assistant supporting the weight of the core,
remove the 3 core mounting bolts. Carefully lower the
core out of the cabinet (see Figure 10).
5. To return core to factory, use crate supplied with exchange
core to protect the element terminals and plate threads.
6. To reinstall, lift the core up into cabinet while an assistant
guides the element wires into the element enclosure
conduit.
7. Position the core and tighten the 3 core mounting bolts.
Tighten the remaining cabinet bolts.
TEMPERATURE HIGHLIMIT
1. Remove temperature high-limit assembly and clean
the inside of the thermowell (see Figure 11). A clean
thermowell will ensure good thermal contact.
2. Use only a factory supplied temperature high-limit to
ensure safe operation.
3. Apply a small drop, 3/32” (2mm) diameter, of heat sink
compound to the center of the metal cap but do not
spread. This is critical for proper thermal contact between
the temperature high-limit and the thermowell (see Figure
11).
4. Reinstall the temperature high-limit assembly with
the snap ring and spring into the thermowell without
damaging the insulating tube. Secure in place with the
cotter pin (see Figure 12).
M OTO R , FA N & FA N G UA R D
1. Remove bolts holding the motor to the motor mount. On
units with a built-in thermostat, remove the bolts on the
back of the thermostat enclosure.
2. Remove conduit #1 located between motor junction
box and control enclosure by turning it in the
direction illustrated (see Figure 13). Note conduits #1 and
- 6 -
FIGURE 13
FIGURE 12
FIGURE 11
FIGURE 10
FIGURE 9
}
Loosen
bolts
only,
do not
remove.
Loosen
bolts
only,
do not
remove.
Element
Enclosure
R e m o v e t h i s
core mounting
b o l t & t w o
others on the
opposite side.
Rotation
Air inlet
Conduit #2 Conduit #1
Remove
Install
Remove
Install
3/32”
(2mm)
Drop
7/8” (22mm)
(From groove to
face of coupling)
Thermowell
Control
Enclosure
Conduit
Junction
Enclosure

#2 are not interchangeable and have left hand threads on
one end, this end is indicated by a machined groove.
3. Remove the 2 piece fan guard assembly (see Figure 14).
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 15). If
difficult to remove, use a gear puller on the fan hub.
6. To reassemble, place motor assembly onto motor mount
and fasten the fan guard to cabinet.
7. Simultaneously engage and tighten both ends of conduit
#1 into enclosures. Leave a 1/16” to 3/16” (1.6 to 4.8
mm) gap between the motor and fan guard (see Figure
16). Adjust conduit #2 to center the fan in the shroud.
8. To ensure a minimum 5 thread engagement, threaded
ends of conduits must protrude a minimum of 1/16”
(1.6mm) into enclosures. The groove on conduit #2 must
not be more than 7/8” (22mm) from motor coupling (see
Figure 13).
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 13).
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 17).
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 8).
C O N T A C T O R
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 8). Individually
terminate all unused wires using closed end connectors.
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”.
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.
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FIGURE 16
FIGURE 15
FIGURE 14
FIGURE 17
1/16” to 3/16”
(1.6 to 4.8mm)

- 8 -
See control
enclosure
assembly
diagram (below)
See high-limit
assembly
diagram
(below)
HEATER ASSEMBLY DIAGRAM
35
36
34
35
34
35
36
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
BUS-BAR CONFIGURATION
ALL 3-PHASE MODELS (EXCEPT 380 VOLT 50 HERTZ)
CONTROL ENCLOSURE
ASSEMBLY DIAGRAM HIGH LIMIT
ASSEMBLY DIAGRAM
Optional built-in
thermostat replaces
item #16

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PA R T S L I S T
FORCED AIR ELECTRIC HEATERS
PART NUMBER
ITEM 2.5-10 kW 12.5-20 kW 20.9-35 kW DESCRIPTION
1 ** ** ** Core
2 3773 3774 3775 Panel, Bottom
3 3776 3777 3778 Panel, Left Side
4 4075 4076 4077 Louver Kit, c/w Screws
5 3770 3771 3772 Panel, Top
6 3779 3780 3781 Panel, Right Side
7 3782 3783 3784 Fan Shroud
8 2.5 - 5.0 kW: 4022 12.5 - 20 kW: 4024 20.9-30 kW: 4025 Fan
6.3 - 10 kW: 4023 35kW: 4026
9 4078 4079 4080 F a n
Guard Kit
37893789
3789Bracket, Motor Mount Right
12 3785 3786 3787 Channel, Motor Mount
13 3788 3788 3788 Bracket, Motor Mount Left
14 Groups D, E, F, & G; IIA : 3737 Groups C, D, F, & G; IIA & IIB: 4590Coupling, Motor
15 3811 3812 3813 Conduit, Motor
16
Groups D, E, F, &
G; IIA : 3838
Groups C, D, F, & G; IIA & IIB: 4983 C/W 5027 Enclosure, Conduit Junction
18 3810 3810 3810 Conduit, Element Enclosure
19 3793 3793 3793 Enclosure, Element
20 3510 3510 3510 Cover, Element Enclosure
21 3790 3790 3790 Panel, Element Enclosure Guard
22 3791 3791 3791 Bracket, Thermostat
23 4983 4983 4983 Enclosure, Thermostat
24 5032 5032 5032 Thermostat, Built-in Kit
25 3524 3525 3526 Enclosure, Control
26 ** ** ** Contactor
27 60 HERTZ: 3612 50 HERTZ: 4416 Transformer
28 3809 3809 3809 Bracket, Printed Circuit Board
29 1876 1876 1876 Terminal, 6-14 ga. Screw Lug
30 3519 3519 3519 Fuse, Buss MDQ-1/4 Amp
31 3514 3514 3514 Printed Circuit Board Assembly
32 3516 3516 3516 Cover, Control Enclosure
33 4082 4082 4082 Temperature High-Limit Kit
34 3816 3816 3816 Bus-Bar, Straight
Please have model and serial number
available before calling.
Groups D, E, F, & G; IIA
208/240V 60 HZ 1 PH: 1377
220V 50 HZ 1 PH: 1377 c/w 4953
480V 60 HZ 1 PH: 2396
208/240/480V 60HZ 3PH: 1862
380/415V 50 HZ 3 PH: 1862
600V 60HZ 3 PH: 1861
Groups C, D, F, & G; IIA & IIB
208/240V 60HZ 1 PH: 4593
208/240/480V 60HZ 3PH: 4594
600V 60 HZ 3 PH: 4595
10 Groups D, E, F, & G; IIA
240/480V 60 HZ 3 PH: 1699
380/415V 50 HZ 3 PH: 1699
600V 60 HZ 3 PH: 2433
Groups C, D, F, & G; IIA & IIB
240/480V 60 HZ 3 PH: 4596
600V 60HZ 3 PH: 4597
Motor, Explosion-Proof
Groups D, E, F, & G; IIA 208/240V 60 HZ 1PH: 3815
220V 50 HZ 1PH: 3815
480V 60 HZ 1PH: 3813
ALL 3PH: 3814
Groups C, D, F, & G; IIA & IIB ALL: 3815
Groups D, E, F, & G; IIA
ALL: 3813
Groups C, D, F, & G; IIA & IIB
ALL: 3815
Conduit, Control Enclosure
17

SPECIFICATIONS FOR ALL 60 HZ MODELS
Nominal kW 3 5 7.5 10 15 20 25 30 35
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 @ 70oF(CFM) 500 850 1750 3600 3950
@ 21oC (m3/hr.) 850 1444 2973 6116 6711
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) 1/4 1/4 1/2
(kW) 0.187 0.187 0.373
Fan Diameter (in.) 12 16 20
(mm) 305 406 508
Net Weight (lbs.) 111 133 154
(kg) 50 61 70
Shipping Weight (lbs.) 151 173 204
(kg) 69 79 93
Enclosures NEMA Type 7 & 9. For dry, indoor use only. Do not immerse in water. Do not
store or use in areas exposed to rain or snow.
Motor Type Explosion-proof. Thermally protected. Permanently lubricated ball bearings.
1725 RPM
Fan Aluminum blade. Steel spider and hub with 5/8 in. (15.875 mm) bore.
Fan Guard Split design with close wire spacing. 1/4 in. (6.3 mm) dia. probe will not enter.
Mounting Holes Two 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.
Temperature High-Limit Automatic reset type, snap-action bimetal, open on temperature rise. Rated
100,000 cycles at 10 amps, handles 0.128 amps.
Control Circuit 120 Volts, 0.128 amps, 15VA. (Grounded)
Optional Built-in Thermostat Explosion-proof. 36
oF to 82oF (2oC to 28oC)
Control Transformer Multi-tap primary, 120 V secondary, 25 VA.
Contactor 40 or 75 amp. Rated for 500,000 mechanical operations. 120 Volts, 15VA coil
(separately fuse-protected).
Heat Transfer Fluid
Long life formulated ethylene glycol and water, freeze protected to -49oF (-45oC).
Cabinet Material 14 ga. (0.075 in.) (1.90 mm) steel. Epoxy coated with five-stage pretreatment,
including iron phosphate.
Core Steel with integral aluminum fins, vacuum charged and hermetically sealed.
Conduit Material Heavy walled, 0.122 in. (3.1 mm) steel, cadmium plated.
Overpressure Protection Preset 100 psig (690 kPa) seep pressure relief valve, aluminum body,
no field serviceable parts.
Temperature Code Rating T3B 165oC(329oF) Class I & II.
Temperature Limitations -49oF to 104oF (-45oC to 40oC).
Storage Limitations -49oF to 176oF (-45oCto 80oC), short term to 248oF (120oC). Do not store or
use in areas exposed to rain or snow. Do not immerse in water.
- 10 -