Voltaire HTC Series User manual

www.voltairesys.com
Phone: [phone]
2900 W. Orange Ave. Ste. 100
Apopka, FL 32703
VoltAire Systems, LLC VoltAire Doc. # BA0117F
Published April 30, 2020
INSTALLATION, OPERATION, AND MAINTENANCE MANUAL FOR
HTC SERIES HEAT EXCHANGERS
Air-to-Air Counter Flow
Heat Exchangers with Capacity of
15W/ºF (27W/ºC), 20W/ºF (36W/ºC), 25W/ºF (45W/ºC),
42W/ºF (75W/ºC) and 90W/ºF (162W/ºC)
48VDC MODELS
UL 1995 and Type 4/4X

HTC Series
Installation, Operation and
Maintenance Manual
VoltAire Systems, LLC
Specifications are subject to change without notice
Page 2 of 21
VoltAire Doc. # BA0117F
Published April 30, 2020
TABLE OF CONTENTS
1. Important Information to Review Prior to Installation, Operation, and Maintenance....................................... Page 3
2. Parts Shipped Loose and Tools Required ..................................................................................................... Page 4
3. Product Description ....................................................................................................................................... Page 5
4. General Product Data .................................................................................................................................... Page 7
5. Installation Instructions .................................................................................................................................. Page 9
6. 48VDC Wiring, Startup and Controls Operation........................................................................................... Page 11
7. Cutout Drawings ......................................................................................................................................... Page 13
8. Electrical Wiring Diagrams........................................................................................................................... Page 16
9. 48VDC Control Board Trouble Shooting...................................................................................................... Page 17
10. Recommended Maintenance ....................................................................................................................... Page 18
11. Spare Parts................................................................................................................................................. Page 19
12. Warranty..................................................................................................................................................... Page 20

HTC Series
Installation, Operation and
Maintenance Manual
VoltAire Systems, LLC
Specifications are subject to change without notice
Page 3 of 21
VoltAire Doc. # BA0117F
Published April 30, 2020
1.IMPORTANT INFORMATION TO REVIEW PRIOR TO INSTALLATION, OPERATION
AND MAINTENANCE
•Read the ENTIRE MANUAL prior to installing and maintaining the heat exchanger. Do not install or
perform maintenance on the heat exchanger if you do not understand all of the instructions. Contact
VoltAire at [phone] with any technical questions or concerns.
•Warning: Improper installation and operation may cause property damage, personal injury or loss of
life. The heat exchanger should only be installed and maintained by a qualified professional in strict
accordance with the requirements within this manual and in accordance with all local, state and federal codes.
•In the event of a conflict, code requirements shall take precedence over the instructions provided within this
manual. The installer should be aware of all code requirements and should fully comply.
•Use care when transporting and lifting the heat exchanger.
•Remove power from the unit during maintenance and installation, as line voltage may be dangerous,
hazardous and lethal.
•Warning: Wear proper personal protection equipment, including but not limited to safety glasses,
goggles and gloves. Edges may be sharp.
•A field provided time delay fuse or breaker must be provided with the power supply circuit serving the heat
exchanger.The installer shall size this fuse or breaker in accordance with all applicable codes. Verify wire
terminals and voltage prior to plugging into the heat exchanger, otherwise you may damage the heat
exchanger's electrical components.
•For 48V DC power supply, verify polarity and apply correctly as improper operating voltage may result in
unit damage.
•These instructions should be retained by the owner and/or with the unit.

HTC Series
Installation, Operation and
Maintenance Manual
VoltAire Systems, LLC
Specifications are subject to change without notice
Page 4 of 21
VoltAire Doc. # BA0117F
Published April 30, 2020
2.PARTS SHIPPED LOOSE AND TOOLS/MATERIALS PROVIDED BY THE INSTALLER
Materials Shipped Loose with the Heat Exchanger
a) Gasket kit
UNIT
PART NUMBER
HTC015*
HTC020*
HTC025*
A6F0002LAA
HTC042*
A6F0007VAA
HTC090*
A6F0005VAA
b) Two (2) M6X25 Threaded Stud with two (2) M6 Nuts and two (2) M6 Lock Washers
c) M6x25 Mounting Bolts
UNIT
QUANTITY
HTC015*
HTC020*
HTC025*
8
HTC042*
8
HTC090*
13
d) ADDITIONAL SHIPPED LOOSE ITEMS
UNIT
DESCRIPTION
48 VDC Models 60" Long Wire Lead with Male Molex Plug
Required Tools and Materials provided by Installer
a) Fuse or Breaker
b) Exterior rated silicone sealant
c) M4 Torx tamper resistant screw driver
d) M6 HEX head screw driver
e) M6 Nut Driver/wrench
f) Torque wrench

HTC Series
Installation, Operation and
Maintenance Manual
VoltAire Systems, LLC
Specifications are subject to change without notice
Page 5 of 21
VoltAire Doc. # BA0117F
Published April 30, 2020
3.PRODUCT DESCRIPTION
VoltAire Systems HTC Series Counter Flow Heat Exchangers are designed for high efficiency and high
performance heat transfer in a closed airflow loop to prevent introduction of exterior air into the
equipment/cabinet. The heat exchangers are an industrial heat management system especially designed for
heat management of electronic enclosures or equipment, including those requiring battery backup. This product
is a passive thermal management system without a refrigeration system and is designed for applications where
the interior temperature may exceed the exterior (ambient) temperature. This product will work in extreme
temperature range from -40ºF to 158ºF (-40ºC to 70ºC).
Figure 1 shows the exterior and interior airflow intake and exhaust locations. Exterior air enters the heat
exchanger through the bottom / front of the unit and exhausts through the front. Interior air enters the intake
through the rear top vents and discharges through the vents below it.
Figure 1 – Heat Exchanger Airflow
The heat exchangers are UL/cUL Recognized per UL 1995/CSA 22.2 NO. 236-15 and UL tested and UL
Recognized for compliance with UL Type 4/4X. HTC Series fans are salt fog certified by a 3rd party per GR-
487-CORE 3.34.1 and ASTM B117 for 720 hours. The aluminum heat exchanger core is coated with epoxy for
additional durability in corrosive atmospheres.
An integrated 48VDC control board is used to control fan speed to optimize energy performance while
minimizing noise. The board is programmed to operate the interior fan based upon the interior temperature
within the cabinet, equipment or building. The interior fan will operate at 25% capacity continuously when the
cabinet isabove 32ºF (0ºC) and below 77ºF (25ºC). At 77ºF (25°C) the interior fan will modulate from 25% to

HTC Series
Installation, Operation and
Maintenance Manual
VoltAire Systems, LLC
Specifications are subject to change without notice
Page 6 of 21
VoltAire Doc. # BA0117F
Published April 30, 2020
100% between 77ºF (25ºC)and 104ºF (40°C). Exterior fan speed control varies based on model. Reference
Figure 10 on page 12 for fan speed design based upon interior temperature.
The 48VDC board includes a general alarm for loss of fan or high temperature (45°C),with Form C dry
contacts withNO or NCalarm output. The 48VDC board is accessible by removing the cover and front panel
on HTC015 to HTC055units as seen in Figure 4. On theHTC090unit, the control board is accessible through
the back interior fan access panel as seen in Figure 5. The 48VDC board includes a test button to verify
operation, as described in Section 6.
The heat exchanger cabinet and internal brackets arefabricated out of acrylume for improved durability. A
powder coated cover isattached with security screws to protect the unit from tampering. The unitiseasily
mounted to a cabinet or equipment with the included field installed gasket and M6 mounting kit. All operable
parts areaccessible through access panels. All units with the exception of the HTC090 are serviceable from the
exterior of the cabinet. The HTC090 is serviced from within the cabinet through the supply and return cutouts.

HTC Series
Installation, Operation and
Maintenance Manual
VoltAire Systems, LLC
Specifications are subject to change without notice
Page 7 of 21
VoltAire Doc. # BA0117F
Published April 30, 2020
4.GENERAL PRODUCT DATA
Figure 2 - Model Nomenclature
Figure 3 - Unit Dimensions
MODEL
NUMBER
NOMINAL
CAPACITY1RATED VOLTAGE FULL LOAD (AMPS) 2 WEIGHT (lbs.)
NOMINAL SIZE
W x H x D (in.)
HTC015B 15 W/ºF (27 W/ºC) 48 VDC 0.5
22 12.3 x 20.0 x 7.6
HTC020B 20 W/ºF (36 W/ºC) 48 VDC 0.8
HTC025B 25 W/ºF (45 W/ºC) 48 VDC 1.7
HTC042B 42 W/ºF (75 W/ºC) 48 VDC 4.3 37 18.0 x 24.0 x 8.0
HTC090B 90 W/ºF (162 W/ºC) 48 VDC 4.8 86 19.4 x 46.3 x 11.3
1
Capacity is nominal based upon free airflow without restrictions; Locating the heat exchanger where airflow is restricted may reduce capacity;
Nominal capacity is at exterior temperature of 113ºF (45ºC) and interior temperature of 131ºF (55ºC), Δ18ºF (Δ10ºC)
2Field provided fuse or breaker is required; Installer shall verify size and insure compliance with all applicable codes.

HTC Series
Installation, Operation and
Maintenance Manual
VoltAire Systems, LLC
Specifications are subject to change without notice
Page 8 of 21
VoltAire Doc. # BA0117F
Published April 30, 2020
Figure 4 – HTC 015-042 Configuration
Figure 5 – HTC 090 Series Configuration

HTC Series
Installation, Operation and
Maintenance Manual
VoltAire Systems, LLC
Specifications are subject to change without notice
Page 9 of 21
VoltAire Doc. # BA0117F
Published April 30, 2020
5. INSTALLATION INSTRUCTIONS
The heat exchanger can be installed on any flat vertical surface.Do not install the unit in a horizontal position
and verify the unit is level.The heat exchanger should be located on a cabinet or equipment such that airflow
is not restricted by obstructions of the interior or exterior intake and exhaust openings.Obstruction of airflow
will reduce capacity of the heat exchanger. Figure 6 illustrates a typical installation.
Using the corresponding cutout template shown in Section 7 prepare the wall for the interior intake and exhaust
openings and fastener locations. Clean the mounting surface to remove any dust, grease and/or debris,
including any metal burrs resulting from metal cutting.
Figure 6 - Typical Installation
Remove the cover from the heat exchanger by removing the M4 Torx security screws on the sides of the cover.
Set the cover to the side as it will not be placed back on the unit until installation is complete.
Using the gasket kit provided, place the gasket on the back of the heat exchanger immediately abutting the
mounting-hole locations. Figure 7 is a general view that reflects the location of the gasket with the hatched
area. Three different lengths of gasket are found in the gasket kit that accompanies the unit. The two longest
strips are used on the sides, the shortest length is used on the bottom and midsection (between the supply and
return openings), and the remaining strip runs across the entire length of the top of the unit. Install the strip that
runs along the top first, then the two sides strips, and finally the middle and bottom strip. Ensure there are no
gaps in the gasket and verify the entire perimeter is sealed with gasket.

HTC Series
Installation, Operation and
Maintenance Manual
VoltAire Systems, LLC
Specifications are subject to change without notice
Page 10 of 21
VoltAire Doc. # BA0117F
Published April 30, 2020
Insert two (2) M6x25 threaded studs provided into the top left and right corner mounting holes on the back of the
unit. These studs are provided to allow the unit to be placed on the cabinet in a temporary manner while the
other fasteners are installed. Do not over-tighten these studs as they will be tightened fully when the nuts are
installed. Install the M6x25 bolts and washer at each of the mounting locations. Install the M6 nuts and washers
on the M6 studs. Tighten the M6 mounting bolts and nuts on the M6 studs to 50 in-lbs torque.
From the exterior, inspect the gasket to verify the gasket is tight and there are no visible leakage points. Using
a field supplied sealant, seal around top, bottom and sides of the heat exchanger against the cabinet. Note that
the heat exchanger is fully maintainable without removal from the cabinet/equipment, therefore this sealant will
not be required to be removed for the purpose of routine maintenance. Therefore use a liberal amount of
sealant. Once the sealant is sufficiently dry, place the heat exchanger cover on the heat exchanger and fasten
with the security screws.
Installation of the heat exchanger is complete, with the exception of applying power and starting the unit per the
instructions below.
Figure 7 – Rear/Back of Counter Flow Heat Exchanger