Solaira Malibu MAL 45240 User manual

Reference Manual
Solaira Malibu
Post Kit with Alpha H1 Heaters
MAL 45240 208/240V 4.5kW (3 1.5kW)
MAL 60240 208/240V 6.0kW (3 2.0kW)
INFORESIGHT CONSUMER PRODUCTS INC.
125 Traders Blvd. E Unit # 4, Mississauga, Ontario L4Z 2H3
Tel [phone] - Fax [phone]
Email [e-mail] - Website www.solairaheaters.com
I M P OR TA N T - S AV E T H E S E I N S T R U C T I O N S F O R F U T U R E R E F E R E N C E
EN
SHORTWAVE INFRARED HEATERS WITH POST & INCOMING TERMINAL BOX KIT
FOR: INDOOR USE - COMMERCIAL AND INDUSTRIAL ONLY
OUTDOOR USE - RESIDENTIAL, COMMERCIAL AND INDUSTRIAL
FOR USE IN NON-HAZARDOUS AREAS ONLY
Post and weatherproof terminal box rain tested to
UL 2021 4th Edition by CSA Montréal Lab.
Alpha H1 Heaters fitted are approved to
CAN.CSA-C22.2 No. 46-13 & UL 2021 3rd Edition.
247748

I M P O R TA N T I N S T R U C T I O N S
I M P O R TA N T I N S T R U C T I O N SI M P O R TA N T I N S T R U C T I O N S
I M P O R TA N T I N S T R U C T I O N S
When using electrical INFRARED HEATERS, basic precautions
should always be followed to reduce the risk of fire, electric shock,
and injury to persons, including the following
2 of 20 Ref No. 043477-EN Rev. A
1. Read all instructions before using this heater.
2. 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.
3. This heater is hot when in use. To avoid burns, do not let bare skin
touch hot surfaces. If provided, use handles when moving this heater.
Keep combustible materials, such as furniture, pillows, bedding,
papers, clothes, and curtains at least 6 feet (1.8m) from the front of the
heater and keep them away from the sides and rear.
4. Extreme caution is necessary when any heater is used by or near
children or invalids and whenever the heater is left operating and
unattended.
5. Do not operate any heater with a damaged cord after the heater
malfunctions, has been dropped or damaged in any manner. Return
heater to authorized service facility for examination, electrical or
mechanical adjustment, or repair.
6. This heater must not be used in bathrooms, laundry areas and similar
locations.
7. Do not run supply cables under carpeting. Do not cover supply cables
with throw rugs, runners, or the like. Arrange cord away from traffic
area and where it will not be tripped over.
8. To disconnect heater, if hard wired switch off breaker. Connect to
grounded CFI outlets only.
9. WARNING - Connect to properly grounded supply.
10. Check that the voltage indicated on the units rating label corresponds
to the mains supply voltage.

3 of 20 Ref No. 043477-EN Rev. A
S AV E T H E S E I N S T RU C T I O N S
S AV E T H E S E I N S T RU C T I O N SS AV E T H E S E I N S T RU C T I O N S
S AV E T H E S E I N S T RU C T I O N S
G R O U N D I N G I N S T R U C T I O N S
For 240 (or 208) volt heaters. The cable from the terminal box must be
hard wired.
11. Do not insert or allow foreign objects to enter any opening as this may
cause an electric shock or fire, or damage the heater.
12. To prevent a possible fire, do not block openings in any manner.
13. A heater has hot parts inside. Do not use it in areas where gasoline,
paint, or flammable liquids are used or stored.
14. Do not cover or otherwise obstruct the heater.
15. Do not use if guard is not present.
16. WARNING - Keep the mains cables away from the body of the heater
and heater heads which will get hot during use.
17. Do not touch the heater during operation as the body becomes
hot and could causes burns. Particular attention has been given
where children and vulnerable people are present.
18. The heater should be fixed to solid and firm ground such as concrete
and the heater heads fixed in their final downward position.
19. The heater is not intended for use by young children and must be
supervised by a responsible person at all times.
I M P O R TA N T I N S T R U C T I O N S
I M P O R TA N T I N S T R U C T I O N SI M P O R TA N T I N S T R U C T I O N S
I M P O R TA N T I N S T R U C T I O N S
Kee combustible material such as furniture, a ers,
clothes and curtains at least 6 feet (1.8m) from the front
of the heater and away from the sides and rear.
W A R N I N G : R I S K O F F I R E
W A R N I N G : R I S K O F F I R EW A R N I N G : R I S K O F F I R E
W A R N I N G : R I S K O F F I R E

I N T R O D U C T I O N
The Malibu outdoor heater produces radiant heat like the sun, warming people and objects
and not the air in between, providing the only form of heat that will not blow away with wind or
drafts. The Malibu is primarily designed for outdoor use and indoor -
commercial and
industrial use.
Please read the enclosed instructions carefully before use. The safety of this heater is
guaranteed only by the correct usage in accordance with these instructions, therefore
it is recommended that they are retained for future reference.
4 of 20 Ref No. 043477-EN Rev. A
WARNING - RISK OF FIRE Do not use as an indoor residential or household heater.
I N S TA L L AT I O N
Use a waterproof supply cable to connect to the heater terminal box. The installation should
be to the local/national electrical code. See the specification table above for the appropriate
supply cable current rating.
WARNING:
Wiring procedures and connections should be in accordance with the
National Electric Code (NEC) and local codes.
WARNING: If the supply cable becomes damaged, it must be immediately replaced by a
qualified person.
CAUTION: Disconnect electric power supply before working on circuit wiring to prevent
electric shock.
CAUTION:
Please observe the minimum safe distance between the heater body and any
inflammable surfaces.
CAUTION: When the electrical connection is outside a weatherproof socket must be used
having ground fault protection (GFCI or GFI).
NOTE: IF IN DOUBT, CONSULT A QUALIFIED ELECTRICIAN.
!
S P E C I F I C AT I O N
T a b l e 1 . C a n a d a a n d U S A H e a t e r s F i t t e d
( a r o v e d t o CAN/CSA-C22.2 No. 46-13 UL 2021 3rd Edition)
Model Voltage Total
Power
No. of
Heaters ×
Power
Total
Current
Min.
Distance
to Ceiling
Min.
Distance to
Side Wall
Dimensions
(H × W × D)
&
Weight
MAL
45240
208 /
240V
3375 /
4500W
3 × 1125 /
1500W
16.2 /
18.8A 59in
(150cm)
8ft × 3ft 4in × 2ft 11in
(244 × 102 × 88cm)
91lb 8oz (41.5kg)
MAL
60240
208 /
240V
4500 /
6000W
3 × 1500 /
2000W
21.6 /
25.0A
19½in
(50cm)

5 of 20 Ref No. 043477-EN Rev. A
K I T C O N T E N T S
DEBRIS PROTECTION
COVER
1 - OFF
POLE & ARM FIXING KIT
1 - OFF
INFILL & COVER FIXING KIT
1 - OFF
BASE PLATE
1 - OFF
BODY POLE
2 - OFF
APPROVED WEATHERPROOF
TERMINAL BOX ASSEMBLY
INCLUDING CERAMIC
BLOCKS & STRAIN RELIEF
GLANDS
1 - OFF
CURVED ARM (TUBE)
3 - OFF
JOINING INSERT
6 - OFF
INFILL PIECE
3 - OFF
ALPHA H1 WEATHER-
PROOF CSA APPROVED
HEATER
3 - OFF
HEATER FIXING KIT
1 - OFF
WIRING CONNECTOR KIT
1 - OFF

6 of 20 Ref No. 043477-EN Rev. A
1. Take the Malibu base plate and place on a work surface to begin mounting the tubes on.
2. Take a curved tube (arm) and slide over a mounting tab. Secure with an M8 screw,
spring washer and plain washer but don’t fully tighten yet.
Fig. 1
Fig. 2a Fig. 2b
AS S E M B LY
C AU T I O N
C AU T I O NC AU T I O N
C AU T I O N
The following rocedure should be carried out by a qualified erson only
in
accordance with the National Electric Code (NEC) and local codes. Ensure the mains
ower su ly is disconnected throughout this assembly rocedure.
3. Fit the other two curved tubes (arms) and once in place fully tighten the screws further.

7 of 20 Ref No. 043477-EN Rev. A
4. Take the terminal box/bracket assembly (Fig. 4) and place in the space where the 3 ×
curved tubes (arms) come together as shown in Fig. 5 with the lid on the top. Note. The nuts
on the two side strain re ief g ands can be removed to provide better access to the screw
s ots.
Fig. 5 Fig. 4
5. Using and M4 screw and shake-proof washer fit the bracket to the arm as shown in Fig. 6.
Repeat with the other two legs.
Fig. 6a Fig. 6b
GROUND
POST

8 of 20 Ref No. 043477-EN Rev. A
7. Fit a Alpha H1 heater to a curved tube by placing the middle bracket of the heater into the
tube opening and push an M8 screw through the underside of the tube. Place a washer and
an M8 Nyloc nut on the end of the screw (Fig. 7a) taking care not to drop the nut down the
tube. Using a 13mm A/F socket, tighten the nut fully by gaining access through the hole in
the top of the tube as shown in Fig. 7b. Repeat with the other two heaters.
Fig. 7a Fig. 7b
8. The heaters should now be mounted (Fig. 8a) so feed the heaters cords down the tube
opening by the brackets so it exits through the large diameter cord hole by the strain relief
glands (Fig. 8b). Ensure rubber grommets are fitted to cord holes in curved arms (tubes).
Fig. 8a Fig. 8b

9 of 20 Ref No. 043477-EN Rev. A
9. Cut the heater cords to the correct length for connecting into the terminal box. Then pass
cords through respective strain relief glands into the box. Strip back cable to relevant length.
Fig. 9 Fig. 10a Fig. 10b
10. Crimp Ø4mm ring terminals (Fig. 10a) to the wires ready for connection (Fig. 10b).
11. Connect the ground wires to the ground post with copper clamps, serrated washers and
M4 nut then wire the heaters to the terminal block as shown in Fig. 11.
Fig. 11
GROUND
POST
INCOMING SUPPLY
CABLE ENTRY
GROUND
POST
INCOMING
SUPPLY
TERMINALS
L1 & L2
2 8/24 V
INCOMING
SUPPLY
TERMINALS
L1 & L2
2 8/24 V

10 of 20 Ref No. 043477-EN Rev. A
12. Fully tighten the strain relief gland nuts and the terminal box lid can be fitted as shown in
Fig. 12.
Fig. 12
13. Fit a zip tie around the curved arms at the base plate to keep them together when the
assembly is moved in the installation stage (on the next page). It is recommended some
cardboard is placed around the tubes before zip tying to protect the painted surface as
shown in Fig. 13.
Fig. 13

SUPPLY
CABLE
2 8/24 V
11 of 20 Ref No. 043477-EN Rev. A
I N S TA L L AT I O N I N S T R U C T I O N S
 Always allow the heater to cool before attempting to reposition/move. Never attempt to
move the heater while it is switched on!
 Observe the minimum safe distance between the heater body and inflammable surfaces
and objects when mounting.
 Please refer to the specification table for the recommended positioning of the heater with
regards to minimum distances. Do not install the heater in a corner!
 Keep out of the reach of children.
 Refer to the page 15 for general sizes and dimensions of the base fixing holes.
1. The terminal box lid can be removed now for installation. The M8 × 20 button head socket
screws and spring washers should be removed and retained while the zip tie should be left
around the curved arms (tubes) until installation is complete. Take the heater assembly off
the base plate and store safely.
CONCRETE
Note. Ensure the base is sitting eve so the heater doesn’t ean when assemb ed.
2. Having made provision for cabling use, consider one of the following options for fixing the
base to a suitable floor
Option 1 Preset 1/2” or 12mm bolts in concrete and fasten .
Option 2 Secure the base with nuts & washers into concrete or other similar material.
Note. Tota weight of heater is 91 b 8oz (41.5kg)
TERMINAL BOX LID
M8 × 2 BUTTON
HEAD SOCKET
SCREWS & SPRING
WASHERS
3 - OFF
STUDS
NUTS &
WASHERS
HOLES
FLOOR
BOLTS &
WASHERS

12 of 20 Ref No. 043477-EN Rev. A
3. Slide a body pole (with joining pieces fitted) onto the three upright pieces on the base
plate by matching the flat faces on the tube with the flat faces of the upright piece, feeding
the supply cable through. Secure in place with 3 X M8 × 20 button head socket screws
placing a M8 spring/split washer behind the head of the screw on all faces.
M8 SPRING/SPLIT
WASHER
3 - OFF
M8 × 2 BUTTON HEAD
SOCKET SCREW
3 - OFF
4. Slide a body pole (with joining pieces
fitted) onto the three joining pieces of the
previously mounted body pole by
matching the flat faces on the tube with
the flat faces of the joining pieces,
feeding the cable through. Secure in
place with 3 X M8 × 20 button head
socket screws placing a M8 spring/split
washer behind the head of the screw on
each face.
SUPPLY
CABLE
2 8/24 V
SUPPLY
CABLE
2 8/24 V

13 of 20 Ref No. 043477-EN Rev. A
5. Feeding the supply cable through the heater assembly, pass the cable through the M25
cable gland and through the terminal box. Locate the heater assembly onto the joining
pieces of the body pole assembly. Secure in place with 3 X M8 × 20mm button head socket
screws, placing M8 spring/split washers behind the heads of the screws.
M8 SPRING/SPLIT WASHER
3 - OFF
M8 × 2 BUTTON HEAD
SOCKET SCREW
3 - OFF
6. Connect the mains supply cable to the connector block and earth post as shown using
ring terminals and keeping the link wires in place as shown. Tighten the strain relief gland
nut fully and replace the terminal box lid and tighten the screws fully to p
revent water
ingress.
GROUND
POST
PRE-WIRED
HEATERS SIDE
SUPPLY
CABLE
2 8/24 V
L1 CONDUCTOR (2 8/24 V)
L2 CONDUCTOR (2 8/24 V)
GROUND
CONDUCTOR
INCOMING
SUPPLY CABLE
2 8/24 V
LINK WIRES
L1
L2
L1 L2

7. Replace the terminal box lid and fit the infill pieces by locating the lower tabs into the
locating tabs on the curved arms. Once located the upper tabs can be screwed into position
with M4 screws and shake-proof washers in the threaded holes. Repeat for the other sides
(total of three).
14 of 20 Ref No. 043477-EN Rev. A
8. The debris protection cover can now be fitted by ensuring the lip on the edges go over the
infill pieces and lining the slots up with the holes in the curved arms. Fix in place with M4
screws and shake-proof washers.
9. Remove the zip tie and check all screws in the individual post sections are fully tightened.
Adjust the heaters to the desired downward positions. Conduct all necessary electrical
safety checks including the ground continuity of the system.
LOWER TABS/
LOCATING TABS UPPER TABS
THREADED HOLES
FOR
DEBRIS COVER (3)
SCREWS FIXING
DEBRIS COVER (3)

15 of 20 Ref No. 043477-EN Rev. A
G E N E R A L S I Z E S

16 of 20 Ref No. 043477-EN Rev. A
Y O U R R E P LA C E M E N T L A M P E M I T T E R
It is important that when ordering a replacement lamp emitter the heater model type is
specified. Failure to fit the correct lamp emitter will cause the heater to fail and become
dangerous in use. Please contact your service agent to purchase your replacement lamp
emitter.
H AN D L I N G T H E R E P L AC E M E N T L AM P E M I T T E R
Your new lamp emitter should be handled with care and without touching the quartz
glass with bare hands. A cotton glove may be used for this purpose. Remove any
finger marks with a soft cloth and methylated spirits or rubbing alcohol. Finger marks
will burn into the lamp emitters quartz glass causing premature failure.
M AI N T E N AN C E
CAUTION: Switch off unit from the mains supply by locking off the breaker
before
replacing a lamp emitter or any maintenance procedure including cleaning.
CAUTION: Should dust or dirt appear on the reflector, it is recommended that that the
guard and lamp emitter are removed and the reflector is wiped with a lint-free cloth before
reassembling (see lamp emitter replacement instructions).
NOTE: For re lacement lam emitters or s are arts lease contact your local
distributor quoting model ty e and rating from rating label. It is very im ortant that
your re lacement lam emitter is exactly the same as the one it was su lied with.
Failure to fit the exact same ty e can cause the heater to rematurely fail.
!

3. Disconnect the lamp emitter wires from the connector block by unscrewing the screws
highlighted above in Fig. B and remove the lamp emitter wires from the connector block.
4. At the back of the heater, remove the plate holding the terminal box by removing the two
fixing screws as shown in Fig. C.
Switch off from the mains to the unit by locking off breaker before any attem ts are
made to re lace a lam emitter. Contact your distributor for the correct re lacement
lam emitter quoting model ty e and rating from rating label. It is im ortant that you
read through the lam emitter re lacement rocedure before commencing.
1. Ensure the heater and lamp emitter are cool and the power supply is disconnected from
the mains supply.
2. Remove the screws from the terminal box at the back of the heater for the lamp emitter to
be replaced and lift off the lid - see Fig. A.
C AU T I O N
C AU T I O NC AU T I O N
C AU T I O N
R E P L AC I N G A L AM P E M I T T E R
Fig. A Fig. B
CONNECTOR BLOCK
17 of 20 Ref No. 043477-EN Rev. A
5. Pull the lamp emitter wires one at a time through the plate to remove as shown in Fig. D.
Fig. C Fig. D
FIXING SCREWS

Fig. E
Fig. F
6. At the front of the heater, gently remove the wire guard by prizing it away from its locating
holes at each end of the heater case (Fig. E).
7. Remove the screw from the side reflector (Fig. F) and lift the side reflector up and away
from the heater. Repeat at the opposite end to remove other side reflector.
8. The lamp emitter wires should be pulled out of the side slots (Fig. G) and the lamp emitter
can be lifted out completely. The wires can then be gently pulled forward so that they come
out from behind the reflector.
SCREW
Fig. G
18 of 20 Ref No. 043477-EN Rev. A

10. Refit the new lamp emitter in reverse order making sure that no wires can get trapped.
Replace both ends side reflectors and their screws ensuring the lamp emitter is held firmly
then fit any other parts.
Fig. H
9. The lamp emitter can now be removed away from the heater leaving it ready to have the
new lamp emitter fitted as shown in Fig. H.
19 of 20 Ref No. 043477-EN Rev. A

IMPORTANT - SAVE THESE
INSTRUCTIONS FOR FUTURE REFERENCE
INFORESIGHT CONSUMER PRODUCTS INC.
125 Traders Blvd. E Unit # 4, Mississauga, Ontario L4Z 2H3
Tel [phone] - Fax [phone]
Email [e-mail] - Website www.solairaheaters.com
Due to our policy of ongoing improvement, we reserve the right to make changes without notice.
© 2019 INFORESIGHT CONSUMER PRODUCTS INC.
Ref No. 043477-EN Issue No. A
247748
Solaira Malibu
Post and weatherproof terminal box rain tested to UL 2021 4th Edition by CSA Montréal Lab.
Alpha H1 Heaters fitted are approved to
CAN.CSA-C22.2 No. 46-13 UL 2021 3rd Edition.