EXHEAT FWD, FWD -T Flameproof Air Warmer, HFT Flameproof Room Thermostat Installation Operation and Maintenance Instructions

INSTALLATION OPERATION AND

MAINTENANCE INSTRUCTIONS FOR

EXHEAT FWD TYPE FLAMEPROOF AIR

WARMER

Please read these instructions thoroughly before installation and ensure they are passed on to

the end-user

1.0 GENERAL

1.1 All work should be carried out by suitable qualified personnel.

1.2 Carefully remove all protective packaging and visually inspect unit for any transit damage.

1.3 Heaters must be handled with care and stored in dry conditions.

1.4

CAUTION – Air warmers over 1m long are HEAVY and must be handled appropriately.

1.5

CAUTION – These heaters are designed for industrial use only and additional personnel protection against contact with hot surfaces may be required in some installations.

1.6 Before connection ensure that the supply corresponds with that specified on the rating label.

1.7 Ensure that the sizes and types of cables to be used are suitably rated for the load and temperature of the unit.

1.8 Each heater must be protected by a suitably rated over current device.

1.9 All prevailing rules, regulations and bylaws in force at the time and place of installation must be observed.

1.10 The heater should be securely fixed in position and all terminal connections checked for tightness before energising.

1.11 Any modification not carried out by Exheat Ltd or its approved agent will invalidate certification and warranty.

1.12 Reference must be made to IEC / EN 60079-17.

1.13 All electrical testing must be carried out in a non-hazardous area.

1.14 Precautions must be taken to prevent damage to machined surfaces and threads of flameproof enclosure.

1.15 The FWD-T model variant includes a factory fitted integral externally adjustable air sensing thermostat.

2.0 INSTALLATION

2.1 The installer or end user shall ensure that the unit has free and unrestricted airflow to allow natural convection to occur.

2.2 At no time is the ambient temperature to be allowed to rise above 40°C (or 60°C for the high ambient version). The recommended method of ensuring this is to install a flameproof room thermostat – Exheat model HFT.

2.3 Orientation of heater must be strictly adhered to. The heater tube must remain horizontal at all times whilst energised.

2.4 The appliance must be securely fitted to a wall or floor using only the brackets provided.

2.5 Threaded (FWD) or spigot (FWD-T) cover flame path surfaces must be checked to ensure that they are undamaged and the ‘O’ ring must be fully located in its groove before refitting.

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3.0 ELECTRICAL SUPPLY CONNECTION

3.1 Please refer to the wiring diagram fig 1.

3.2 The cable entries are M20 and positioned on the side of the terminal box.

3.3 The cables must enter the FWD heater terminal box via a certified Ex d cable gland (not supplied) to suit the cable, and be fitted by a suitably qualified person.

3.4 The installer or end-user must connect to the heater terminals within the terminal box - DO

NOT connect to or disturb factory fitted heating element wires.

3.5 FWD only: the cover of the FWD terminal box is unscrewed after slackening a locking grub screw using a 3mm A/F hex key. When re-fitting ensure that the ‘O’ ring seal is in good condition and correctly located. The cover threads MUST be kept clean and free from any debris at all times.

3.6 FWD-T only: the cover of the FWD-T terminal box is opened after the three socket head screws have been removed. When re-fitting ensure that the ‘O’ ring seal is in good condition and correctly located. The cover spigot mating faces MUST be kept clean and free from any debris at all times.

3.7 FWD-T only: the terminal box of the FWD-T may be rotated as necessary for alignment purposes only while the cover is removed. Slacken the 3-off grub screws in the locking ring inside the base of the terminal box and then rotate the locking ring anti-clockwise sufficiently to allow re-alignment of the terminal box. The locking ring is tightened by rotating clockwise. The 3-off grub screws in the ring must be re-tightened before the terminal box cover is re-fitted.

4.1

WARNING – the heater MUST BE EARTHED.

4.2 The external earth connection is located on the outside of the terminal box.

4.3 The internal earth connection is via a pillar inside the terminal box (see fig 1).

5.0 OPERATION

5.1 WARNING – The Air Warmer must at no time be covered during operation, as this could lead to dangerous overheating.

5.2 Once energized the Air Warmer will continue to operate until de-energised by an external control device (available separately).

5.3 FWD-T only: the control located on the terminal box cover may be adjusted until the heater de-energises at the desired air temperature.

5.4 The permitted ambient temperature range for operation of the standard FWD Air Warmers is -20°C ≤ T amb

≤ +40°C. A special high ambient version (up to +60°C) is available, identified by marking of the extended ambient temperature range. The end user must ensure that no excursions outside these ambient temperature limits are allowed to occur at any time.

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6.0 MAINTENANCE

6.1 All prevailing site safety regulations shall be adhered to at all times.

6.2 Before and whilst any maintenance activity is carried out, it must be ensured that there are no hazardous gases present.

6.3 Equipment is to be fully isolated from the electrical supply before and whilst any work is being carried out.

6.4 Any damage or faults should be notified to Exheat Ltd immediately.

6.5 Any replacement parts required must be obtained directly from Exheat. The use of any other parts will void any certification and warranty.

6.6 Reference must be made to IEC / EN60079-17 (especially table 1) in addition to the following recommendations: a. Generally inspect the equipment for external damage. b. Ensure that the spaces between the element fins remain clear and that the airflow remains unrestricted. a. Isolate the electrical supply and remove the cover. b. Internals should be clean and dry. d. Heating element insulation resistance to be at least 2 megohm. e. Refit cover with new ‘O’ ring if required (note – this must be secured in place using

RTV sealant supplied with the replacement ‘o’-ring. f. Earth continuity must be maintained between all earth points and main structure.

6.6.3 Annually a. Check all above. b. Check for element failure or low insulation resistance.

6.6.4 If heaters are being left unused for a period greater than 3 months, carry out 6 monthly maintenance before energising.

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6.7 Removal and Replacement of Ceramic Core Type Heating Element.

6.7.1 Slacken lid locking grub screw and unscrew cover.

6.7.2 Disconnect electrical connections and remove cables to heater.

6.7.3 Release the clamp securing heater element.

6.7.4 Carefully withdraw heating element from its tube.

6.7.5 Ensure the tube is clean and dry internally.

6.7.6 Carefully fit replacement heating element through a new sealing gasket and into tube whilst preventing it from bending and protecting it from mechanical shock.

6.7.7 Re-assemble heater and re-connect wiring (reverse of 6.7.1 to 6.7.3.)

6.7.8 Carry out 6 Monthly checks as above.

7.0 Marking and certification reference

7.1 II 2 G/D (ATEX certified units only)

Ex d IIC T4, T3 or T2

Ex tD A21 IP66 T135, T200 or T300ºC

Do not open while energised

Do not open in presence of explosive atmosphere

If the temperature at the conduit entry exceeds 70ºC high temperature cable must be used

LCIE 04 ATEX 6016 X (ATEX certified units)

IECEx LCI 07.0005X (IECEx certified units)

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Fig.1

WIRING DIAGRAM

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EXHEAT LTD

Threxton Road Industrial Estate

Watton, Thetford, IP25 6NG

Tel: +44 (0)1953 886200

Fax: +44 (0)1953 886222

For sales and new product information see our website www.exheat.com

2006/95/EC

89/336/EEC

(As amended by 92/31/EEC & 93/68/EEC)

94/9/EC

Stock Code S090-00-0000-0029

Issue E

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