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.

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)

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.

- 2 -

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

- 3 -

FIGURE 1

EXTERIOR WALL

WALL

EXTERIOR

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)

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)

- 5 -

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.

- 7 -

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

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

- 9 -

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

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

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 -

- 11 -

SPECIFICATIONS FOR ALL 50 HZ MODELS

Nominal kW 2.5

3.7&4.2 6.3&7.5

8.4

12.5&12.6 14.9&16.7

20.9 22.4

Max. Altitude (ft.) 12,000 8,000 10,000 7,000 10,000 7,000 10,000 7,000

(m) 3,658 2,438 3,048 2,134 3,048 2,134 3,048 2,134

Air Flow @ 70oF(CFM) 400 700 1450 3000

@ 21oC(m3/hr.) 679 1189 2463 5096

Horizontal Air Throw (ft.) 13 25 35 60

(m) 4.0 7.6 10.7 18.2

Max. Mounting Height (ft.) 7 10 10 20

(to underside) (m) 2.1 3.0 3.0 6.1

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.

1425 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 0.130 amps.

Control Circuit 115 Volts, 0.130 amps, 15VA. (Grounded)

Optional Built-in Thermostat Explosion-proof. 36

oF to 82oF (2oC to 28oC)

Control Transformer Multi-tap primary, 115 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 (-45oCto 40oC).

Storage Limitations -49oF to 176oF (-45oC to 80oC), short term to 248oF (120oC). Do not store

or use in areas exposed to rain or snow. Do not immerse in water.

- 12 -

XL412-208160-3 208 3 1 14.4 19 10.5 20 4044 3618

XL412-240160-3 240 3 1 12.5 19 10.5 20 4045 3618

XL412-208360-3 208 3 3 8.3 19 10.5 15 4044 3618

XL412-240360-3 240 3 3 7.2 19 10.5 15 4045 3618

XL412-480160-3 480 3 1 6.3 19 10.5 15 4046 3618

XL412-480360-3 480 3 3 3.6 19 10.5 15 4046 3618

XL412-600360-3 600 3 3 2.9 19 10.5 15 4047 3618

XL412-208160-5 208 5 1 24 31.6 17.6 35 4048 3618

XL412-240160-5 240 5 1 20.8 31.6 17.6 30 4049 3618

XL412-208360-5 208 5 3 13.9 31.6 17.6 20 4048 3618

XL412-240360-5 240 5 3 12 31.6 17.6 20 4049 3618

XL412-480160-5 480 5 1 10.4 31.6 17.6 15 4050 3618

XL412-480360-5 480 5 3 6 31.6 17.6 15 4050 3618

XL412-600360-5 600 5 3 4.8 31.6 17.6 15 4051 3618

XL412-208160-7.5 208 7.5 1 36.1 27.9 15.5 50 4052 3619

XL412-240160-7.5 240 7.5 1 31.3 27.9 15.5 40 4053 3618

XL412-208360-7.5 208 7.5 3 20.8 27.9 15.5 30 4052 3618

XL412-240360-7.5 240 7.5 3 18 27.9 15.5 25 4053 3618

XL412-480160-7.5 480 7.5 1 15.6 27.9 15.5 20 4054 3618

XL412-480360-7.5 480 7.5 3 9 27.9 15.5 15 4054 3618

XL412-600360-7.5 600 7.5 3 7.2 27.9 15.5 15 4055 3618

XL412-208160-10 208 10 1 48.1 37.2 20.6 70 4056 3619

XL412-240160-10 240 10 1 41.7 37.2 20.6 60 4057 3619

XL412-208360-10 208 10 3 27.8 37.2 20.6 35 4056 3618

XL412-240360-10 240 10 3 24.1 37.2 20.6 35 4057 3618

XL412-480160-10 480 10 1 20.8 37.2 20.6 30 4058 3618

XL412-480360-10 480 10 3 12 37.2 20.6 20 4058 3618

XL412-600360-10 600 10 3 9.6 37.2 20.6 15 4059 3618

XL416-240160-15 240 15 1 62.5 27.1 15 80 4061 3619

XL416-208360-15 208 15 3 41.6 27.1 15 60 4060 3619

XL416-240360-15 240 15 3 36.1 27.1 15 50 4061 3619

XL416-480160-15 480 15 1 31.3 27.1 15 40 4062 3618

XL416-480360-15 480 15 3 18 27.1 15 25 4062 3618

XL416-600360-15 600 15 3 14.4 27.1 15 20 4063 3618

XL416-208360-20 208 20 3 55.5 36.1 20.1 70 4064 3619

XL416-240360-20 240 20 3 48.1 36.1 20.1 70 4065 3619

XL416-480160-20 480 20 1 41.7 36.1 20.1 60 4066 3619

XL416-480360-20 480 20 3 24.1 36.1 20.1 35 4066 3618

XL416-600360-20 600 20 3 19.2 36.1 20.1 25 4067 3618

XL420-240360-25 240 25 3 60.1 21.9 12.2 80 4068 3619

XL420-480360-25 480 25 3 30.1 21.9 12.2 40 4069 3618

XL420-600360-25 600 25 3 24.1 21.9 12.2 35 4070 3618

XL420-480360-30 480 30 3 36.1 26.3 14.6 50 4071 3619

XL420-600360-30 600 30 3 28.9 26.3 14.6 40 4072 3618

XL420-480360-35 480 35 3 42.1 28 15.6 60 4073 3619

VOLTAGE

(V)

NOMINAL

WATTAGE

(kW) PHASE

TOTAL

CURRENT

(A)

TEMPERATURE RISE

CORE PART

NUMBER

MAXIMUM

FUSE SIZE

A

CONTACTOR

PART

NUMBER

oFoC

NOTES:

1. Heater is functioning normally if at rated voltage the amp draw is within 10% of the value in this table.

2. Operation at lower voltages will result in reduced heat output and amp draw.

TECHNICAL DATA FOR ALL CSA CERTIFIED

60 HZ ELECTRIC AIR HEATERS

MODEL

- 13 -

XL412-220150-2.5 220 2.5 1 11.4 19.7 11 15 4045 3618

XL412-220150-4.2 220 4.2 1 19.1 33.2 18.4 25 4049 3618

XL412-220150-6.3 220 6.3 1 28.6 28.4 15.8 40 4053 3618

XL412-220150-8.4 220 8.4 1 38.2 37.9 21.1 50 4057 3619

XL416-220150-12.6 220 12.6 1 57.3 27.5 15.3 80 4061 3619

XL412-380350-2.5 380 2.5 3 3.8 19.7 11 15 4045 3618

XL412-380350-4.2 380 4.2 3 6.4 33.2 18.4 15 4049 3618

XL412-380350-6.3 380 6.3 3 9.6 28.4 15.8 15 4053 3618

XL412-380350-8.4 380 8.4 3 12.8 37.9 21.1 20 4057 3618

XL416-380350-12.5 380 12.5 3 19 27.2 15.1 25 4061 3618

XL416-380350-16.7 380 16.7 3 25.4 36.4 20.2 35 4065 3618

XL420-380350-20.9 380 20.9 3 31.8 22 12.2 40 4068 3618

XL412-415350-3.7 415 3.7 3 5.1 29.2 16.2 15 4050 3618

XL412-415350-7.5 415 7.5 3 10.4 33.9 18.8 15 4058 3618

XL416-415350-14.9 415 14.9 3 20.7 32.5 18 30 4066 3618

XL420-415350-22.4 415 22.4 3 31.2 23.6 13.1 40 4071 3618

VOLTAGE

(V)

NOMINAL

WATTAGE

(kW) PHASE

TOTAL

CURRENT

(A)

TEMPERATURE RISE

CORE

PART

NUMBER

MAXIMUM

FUSE SIZE

A

CONTACTOR

PART

NUMBER

oFoC

NOTES:

1. Heater is functioning normally if at rated voltage the amp draw is within 10% of the value in

this table.

2. Operation at lower voltages will result in reduced heat output and amp draw.

TECHNICAL DATA FOR ALL CSA CERTIFIED

50 HZ ELECTRIC AIR HEATERS

MODEL

- 14 -

XL412-208160-3 208 3.0 1 2.3 13.0 15.3 19.1 12 20 19.0 10.5 4044 3618

XL412-240160-3 240 3.0 1 2.3 11.2 13.5 16.9 12 20 19.0 10.5 4045 3618

XL412-208360-3 208 3.0 3 1.4 7.5 8.9 11.1 14 15 19.0 10.5 4044 3618

XL412-240360-3 240 3.0 3 1.4 6.5 7.9 9.9 14 15 19.0 10.5 4045 3618

XL412-480360-3 480 3.0 3 0.7 3.2 3.9 4.9 14 15 19.0 10.5 4046 3618

XL412-208160-5 208 5.0 1 2.3 22.6 24.9 31.1 8 35 31.6 17.6 4048 3618

XL412-240160-5 240 5.0 1 2.3 19.6 21.9 27.4 10 30 31.6 17.6 4049 3618

XL412-208360-5 208 5.0 3 1.4 13.0 14.4 18.1 12 20 31.6 17.6 4048 3618

XL412-240360-5 240 5.0 3 1.4 11.3 12.7 15.9 12 20 31.6 17.6 4049 3618

XL412-480360-5 480 5.0 3 0.7 5.7 6.4 8.0 14 15 31.6 17.6 4050 3618

XL412-208160-7.5 208 7.5 1 2.3 34.6 36.9 46.1 8 50 27.9 15.5 4052 3619

XL412-240160-7.5 240 7.5 1 2.3 30.0 32.3 40.4 8 45 27.9 15.5 4053 3618

XL412-208360-7.5 208 7.5 3 1.4 20.0 21.4 26.8 10 30 27.9 15.5 4052 3618

XL412-240360-7.5 240 7.5 3 1.4 17.3 18.7 23.4 10 25 27.9 15.5 4053 3618

XL412-480360-7.5 480 7.5 3 0.7 8.7 9.4 11.8 14 15 27.9 15.5 4054 3618

XL412-240160-10 240 10.0 1 2.3 40.4 42.7 53.4 6 60 37.2 20.6 4057 3619

XL412-208360-10 208 10.0 3 1.4 26.9 28.3 35.4 8 40 37.2 20.6 4056 3618

XL412-240360-10 240 10.0 3 1.4 23.3 24.7 30.9 8 35 37.2 20.6 4057 3618

XL412-480360-10 480 10.0 3 0.7 11.7 12.4 15.5 12 20 37.2 20.6 4058 3618

XL416-208360-15 208 15.0 3 1.4 40.0 41.4 51.8 6 60 27.1 15.0 4060 3619

XL416-240360-15 240 15.0 3 1.4 34.6 36.0 45.0 8 45 27.1 15.0 4061 3619

XL416-480360-15 480 15.0 3 0.7 17.3 18.0 22.5 10 25 27.1 15.0 4062 3618

XL416-480360-20 480 20.0 3 0.7 23.3 24.0 30.0 10 30 36.1 20.1 4066 3618

XL420-480360-25 480 25.0 3 1.0 29.1 30.1 37.6 8 40 21.9 12.2 4069 3618

XL420-480360-30 480 30.0 3 1.0 35.1 36.1 45.1 8 50 26.3 14.6 4071 3619

XL420-480360-35 480 35.0 3 1.0 41.1 42.1 52.6 6 60 28.0 15.6 4073 3619

VOLTAGE

(V)

NOMINAL

WATTAGE

(kW) PHASE

MOTOR

CURRENT

(A)

HEATER

ELEMENT

CURRENT

(A)

TOTAL

CURRENT

(A)

MINIMUM

CIRCUIT

AMPACITY

(A)

SUPPLY

WIRE

SIZE

(AWG.)

MAX.

CIRCUIT

FUSE

(A)

TEMPERATURE RISE

CORE PART

NUMBER

CONTACTOR

PART

NUMBER

oFoC

NOTES:

1. Minimum conductor size for 30oC (86oF) ambient. Derate conductor for ambient temperature. Use minimum 90oC (194oF) 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.

XL4 TECHNICAL DATA FOR UL LISTED 60 HZ, GROUPS D, E, F, & G; IIA MODELS

MODEL

XL412-208160-3 208 3.0 1 2.7 13.0 15.7 19.1 12 20 19.0 10.5 4044 3618

XL412-240160-3 240 3.0 1 2.7 11.2 13.9 16.9 12 20 19.0 10.5 4045 3618

XL412-208360-3 208 3.0 3 1.4 7.5 8.9 11.1 14 15 19.0 10.5 4044 3618

XL412-240360-3 240 3.0 3 1.4 6.5 7.9 9.9 14 15 19.0 10.5 4045 3618

XL412-480360-3 480 3.0 3 0.7 3.2 3.9 4.9 14 15 19.0 10.5 4046 3618

XL412-208160-5 208 5.0 1 2.7 22.6 25.3 31.1 8 35 31.6 17.6 4048 3618

XL412-240160-5 240 5.0 1 2.7 19.6 22.3 27.4 10 30 31.6 17.6 4049 3618

XL412-208360-5 208 5.0 3 1.4 13.0 14.4 18.1 12 20 31.6 17.6 4048 3618

XL412-240360-5 240 5.0 3 1.4 11.3 12.7 15.9 12 20 31.6 17.6 4049 3618

XL412-480360-5 480 5.0 3 0.7 5.7 6.4 8.0 14 15 31.6 17.6 4050 3618

XL412-208160-7.5 208 7.5 1 2.7 34.6 37.3 46.1 8 50 27.9 15.5 4052 3619

XL412-240160-7.5 240 7.5 1 2.7 30.0 32.7 40.4 8 45 27.9 15.5 4053 3618

XL412-208360-7.5 208 7.5 3 1.4 20.0 21.4 26.8 10 30 27.9 15.5 4052 3618

XL412-240360-7.5 240 7.5 3 1.4 17.3 18.7 23.4 10 25 27.9 15.5 4053 3618

XL412-480360-7.5 480 7.5 3 0.7 8.7 9.4 11.8 14 15 27.9 15.5 4054 3618

XL412-240160-10 240 10.0 1 2.7 40.4 43.1 53.4 6 60 37.2 20.6 4057 3619