Chromalox CXH-A/B Hazardous Location Unit Heater Installation Manual

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Chromalox CXH-A/B Hazardous Location Unit Heater Installation Manual | Manualzz

Installation, Operation and Maintenance Instructions

CXH

-

A/B Hazardous Location Forced

-

Air Heater

© 2020 Chromalox,

PF490CE 3

161 302421 007

August 2020

Table of Contents

1.

Introduction

2.

Safety

3.

Specifications and Product Identification

4.

Mechanical Installation

5.

Electrical Installation

6.

Operation

7.

Preventative Maintenance and Repair

8.

Troubleshooting

9.

Warranty

© 2020 Chromalox,

1. Introduction

This document contains safety, installation, operation, maintenance, and troubleshooting information for model CXH

-

A/B unit heaters. Always check www.chromalox.com to ensure you have the latest revision of this document. Revision date is listed on the cover page.

2. Safety

Read this First

Read this document in full prior to installation and commissioning as it contain important safety and warning information that can prevent injury, death, and damage to property. Model CXH-A/B heaters meet the requirements of ATEX directive 2014/34/EU and IECEx schemes. They are designed for space heating and freeze protection in hazardous locations where potentially flammable gasses may be found.

Routine preventative maintenance is required to ensure safe and reliable operation.

Qualified Personnel

Installation and servicing should be performed by qualified personnel only. Qualified personnel should be familiar with electrical installations in hazardous locations. Installation should be in accordance to the latest issues of the relevant parts of EN60079 as well as local codes.

Electric Shock Hazard

Disconnect all power before installing or servicing heater. Failure to do so could result in personal injury or property damage.

Flameproof Enclosures

Only remove enclosure covers when it can confirmed that flammable gases or dust are not present.

Flameproof Enclosures: This heater is designed for use in hazardous locations and contains enclosures with flameproof joints. Unless otherwise noted, do not tamper with, repair, or modify enclosures or the enclosures flameproof joints. If the flameproof joints

(threads or machined surfaces) appear to be damage, units must be returned to Chromalox for repair. If stripped or damaged, replacement fasteners used on flameproof enclosures must be provided by Chromalox.

Indicator Lights: If the lens becomes damaged or detached then the Indicator Lamp should be replaced.

© 2020 Chromalox,

Hot Surfaces

During operation, surfaces of the heater may become hot and pose a potential burn risk. Prior to inspecting or servicing wait until surfaces have cooled below 40°C.

Motor and Fan Blade

Motor and fan blade rotate at high speed during operation. Never remove protective grill during operation. Before servicing ensure that blade and motor have come to a complete stop.

When stored or used at -40C, inspect the motor prior to and after use .

Noise Levels

During operation, model CXH-A/B heaters produce noise levels of approximately 82dB. It is recommended that personnel working in close proximity to operating equipment be equipped with hearing protection to prevent hearing damage or loss.

Glycol Heat Transfer Fluid

Model CXH-A/B heater utilize propylene or ethylene glycol in the sealed heat exchanger. Material Safety Data Sheets (MSDS) can be located at www.chromalox.com.

Electrostatic Charging Hazard

The accumulation of dust and dirt on painted heater surfaces can potentially lead to electrostatic charging. Per preventative maintenance and repair section, only clean painted surfaces with a wet, damp cloth.

3. Specifications and Product Identification

Table A: Operating Performance

Note: Performance data is based on results of controlled testing. Actual performance may vary depending on application.

© 2020 Chromalox,

3. Specifications and Product Identification Cont.

Temperature

Limitations

Enclosures

Conduit

Optional Thermostat

Optional Pilot Lights

Operating

Storage

Flame proof, Aluminum

Galvanized, Heavy Walled

Flame proof, 50 90°F (10 32°C)

Indicates Heat on, Heater Fault

40°C to + 40°C ( 40°F to 104°F);

Intermittently to 130°C (266°F)

Model CXH-A/B heaters have an EC type examination as well as IECEx and EAC certificates issued by Intertek and have been approved to the following standards

EN 60079-0:2012+A11:2013

EN 60079-1:2014

IEC 60079-0:2011 (Ed. 6)

IEC 60079-1:2007-04 (Ed. 6)

© 2020 Chromalox,

3. Specifications and Product Identification Cont.

© 2020 Chromalox,

4. Mechanical Installation

Location

Model CXH-A/B heaters are certified for hazardous locations listed in table C. When un-crating confirm nameplate (located on control enclosure lid on left side of heater) matches what was ordered. If listing does not meet hazardous location requirements, contact Chromalox immediately.

Prior to installation ensure that heater configuration meets environmental requirements. Model CXH-A/B heater are designed with corrosion and moisture protection, but it is the responsibility of the end user to ensure that materials are compatible with the application conditions.

Location should be free of interference from umns, machinery and

Figure 1: Mounting Location

Outlet air is hot, so avoid locations where heaters may blow directly at personnel.

For best performance, locate heaters according to figure 1.

This will promote optimal air circulation and eliminate hot or cold spots. Heaters should blow air parallel to exposed walls

(do not blow directly at and should be installed along the windward side when installed in a building exposed to a prevailing

Mounting

heaters are designed for use only in a permanently mounted upright position. The maximum out of plane dimensions as shown in Figure 2 must not be exceeded in either during operation and installation. to comply may cause nuisance tripping of over-temperature cutout

The ceiling or wall mounting surface and the anchoring must be sufficient to support the combined weights the heater and mounting hardware (heater weights are listed in

Table A).

Heaters may be mounted at any convenient height above floor.

The minimum spacing shown in Figure 3 should maintained to adjacent walls and ceiling. If floor heat is sired, do not mount higher than 8 to 10 feet 2.4 to 3.0 meters) above

.

Controlling thermostats to individual heaters should mounted at shoulder height on inside walls or columns clear of the discharge air stream of the unit. Allow at least in front of heater for air stream to discharge freely.

Do not mount mercury type thermostat directly on unit, vibration could cause

Heater may be mounted on a shelf or stand from the

Be sure that mounting clearances are maintained and bottom of unit has at least 1” (25mm) clearance underneath it. This is necessary for good air circulation and servicing of heat exchanger. All mounting methods must allow for removal front

.

© 2020 Chromalox,

4. Mechanical Installation Cont.

Mounting Cont.

Mounting and anchoring provisions must take into count the unit vibration and cantilevered loading when wall pole mounted. Heater weights are listed in tables A and B within the Specifications and Product Identification section of the manual

For proper mounting support, it is recommended that a Chromalox supplied wall, ceiling, or pole mounting kit be utilized.

These kits include brackets and heater installation hardware.

Refer to document PF458 for mounting kit installation.

CXH-A/B heaters are equipped with two threaded mounting points ( 5/8-11 UNC) located on the top of the heater case that may used to be anchor the heater to an alternative mounting structure using 5/8-11 (UNC) bolts and lock-washers.

Figure 2: Maximum Out of Plane Dimensions

Figure 3: Installation Clearances

Figure 4: Mounting Holes

© 2020 Chromalox,

Heater Model

CXH A/B 03S to CXH A/B 10S

CXH A/B 10M to CXH A/B 20M

CXH A/B 25L to CXH A/B 35L

Dimensions in. (mm)

D

17-5/8 (447.7)

21-5/8 (533.4)

25-5/8 (635)

5. Electrical Installation

Prior to Installation

Follow all safety guidelines in this manual when performing electrical wiring. Electrical installation should be conducted by qualified personnel.

Model CXH-A/B heaters must be installed according to the latest editions of the relevant parts of EN60079.

Disconnect power to unit prior to installation. If integral disconnect is being serviced, ensure that feeder service to disconnect is off.

Familiarize yourself with wiring diagram and wire connection points. Wiring diagrams are located on the inside cover of the main control enclosure. A general wiring diagram is also included in this manual.

Ensure that proper cable glands and conduit connectors have been selected. Cable, glands and conduit must be installed per IEC/ATEX guidelines and must have proper hazardous

Mains Connection

The conduit / cable entry for mains power are located on the cast control enclosure.

To access the connection points for the mains power, remove the (18) x M12 cover bolts on the main enclosure. Once removed, the (3) mains wires should be connected directly to the heater contactor or circuit breaker (if equipped). See figures 5 and 6 for connection points.

Figure 5: Mains Power Conduit/Cable Entries

location listings.

1”NPT Entry on top is factory equipped with a non -certified conduit plug

Unused conduit/cable entries must be plugged with certified stopper plugs.

Ensure that equipment is properly grounded using designated grounding lugs.

Modification of cable/conduit entries will void third party listings and warranty.

Wiring should be selected based on amperages listed in table

D. Use only copper conductors and approved wiring methods.

An external overcurrent device is required. Overcurrent device should be sized based on heater amperages listed in table D and should conform to installation location requirements.

Figure 6: Mains Power Connection

© 2020 Chromalox,

5. Electrical Installation Cont.

© 2020 Chromalox,

Diagram 1

CXH

-

A/B

-

03

CXH

-

A/B

-

05

CXH

-

A/B

-

07

CXH

-

A/B

-

10

CXH

-

A/B

-

15

CXH

-

A/B

-

03

CXH

-

A/B

-

05

CXH

-

A/B

-

07

CXH

-

A/B

-

10

CXH

-

A/B

-

15

CXH

-

A/B

-

20

CXH

-

A/B

-

25

CXH

-

A/B

-

30

CXH

-

A/B

-

35

CXH

-

A/B

-

03

CXH

-

A/B

-

05

CXH

-

A/B

-

07

CXH

-

A/B

-

10

CXH

-

A/B

-

15

CXH

-

A/B

-

20

CXH

-

A/B

-

25

CXH

-

A/B

-

30

CXH

-

A/B

-

35

5. Electrical Installation Cont.

Table D: Electrical Ratings

Model

600

600

600

600

600

600

600

600

600

480

480

480

480

480

480

480

480

480

240

240

240

240

240

Voltage kW Phase

Total

Current

(Amps)

3.2

5.6

7.5

10.4

15.2

20.0

24.7

29.6

34.4

18.5

24.5

30.9

36.9

42.9

4.0

6.4

8.8

12.4

8.0

12.8

17.6

24.8

36.9

3

5

7.5

10

15

20

25

30

35

15

20

25

30

35

3

5

7.5

10

3

5

7.5

10

15

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

Minimum

Circuit

Amps

4.0

7.0

9.4

13.0

19.0

25.0

30.9

37.0

43.0

23.2

30.7

38.7

46.2

53.7

5.0

8.0

11.0

15.5

10.0

16.0

22.0

31.0

46.2

Supply Wire

(AWG)

(90˚C Ambient)

14

14

14

14

14

12

8

8

6

10

8

8

6

4

14

14

14

14

14

14

12

8

6

Max Fuse/Breaker

Size (Amps)

Wiring

Diagram

15

15

15

15

20

25

35

40

50

30

35

40

50

60

15

15

15

20

15

20

25

35

50

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

© 2020 Chromalox,

6. Operation

General

The CXH-A/B unit heaters use a sealed water-glycol filled heat exchanger. The electric immersion elements transfer heat energy directly to the fluid generating a fluid/vapor mixture which releases its heat energy to the finned radiator as it rises and condenses back to the bottom reservoir to be reheated. This cycle will continue as long as fan forced air is available on the finned structure to remove the heat to the airstream.

The finned structure of the heat exchanger must be kept clean and free of accumulated dust and dirt. The cabinet front panel is easily removed providing access to the heater core for periodic cleaning.

Startup

Prior to startup, ensure that heater has been properly installed per this manual and local requirements.

When starting up after long period of in-operation, ensure that proper maintenance procedures have been performed. Not following preventative maintenance procedures can lead to potential dangerous operating conditions.

Unit should not be operated with louvers fully closed. Mechanical stops are incorporated into the design of the cabinet to limit the degree of closure. Do not force the louvers beyond these stops.

If specified, units are supplied with built in alarm pilot lamps which will energize when abnormal conditions occur. Review troubleshooting section for information on addressing these situations.

Do not operate in ambient temperatures exceeding 40°C

(104°F).

Stand clear of front of heater to avoid possible injury.

Unless fitted with the optional 3 position selector switch, heater should immediately start once power is supplied.

In temperatures below -20°C, the fan may not begin rotating for several seconds. This is normal as the motor and heat exchanger must heat up the entire unit in order for it to begin rotating.

Manual and Automatic Reset Thermal Cutout

High temperature cutout(s) must never be bypassed in control circuit. The factory must perform the replacement of the immersion heater or high temperature cutout. The heat e changer seal must not be broken. Consult factory for service.

Resetting the manual cutout multiple times without resolving the cause of the tripping may allow the heater to operate in an unsafe condition. Failure to investigate and resolve a trip condition could result in personal injury or property damage.

The automatic and manual reset limit controls are located in the heating element hazardous location enclosure on the heat exchanger which is covered by the sheet metal housing attached to the side of the unit.

To gain access, remove the four sheet metal screws holding the sheet metal cover in place and unthread the cast aluminum enclosure lid.

© 2020 Chromalox,

The manual reset limit control device has a small reset button protruding from the center of its back housing.

Depress this button in to reset the control. Replace the aluminum enclosure lid and sheet metal cover.

The automatic reset limit control does not require resetting. If nuisance tripping occurs, consult maintenance and troubleshooting sections. Do not try to remove or replace.

6. Operation Cont.

Optional Integral Thermostat

Do not tamper with or remove thermostat terminal cover. Thermostat may only be serviced by Chromalox personnel.

Thermostats have a set range from 50-90°F (10-32°C).

To set the thermostat rotate dial to desired temperature

© 2020 Chromalox,

7. Preventative Maintenance

General

Review all guidelines as well as safety and warning information before performing maintenance and repairs.

Maintenance and repairs should be performed by qualified personnel only.

Improper maintenance or repair can result in injury and destruction of property and may result in warranty becoming null and void.

Disconnect unit from power before performing repairs

If during inspection, damage to threaded entries and/or flame paths is located, do not repair. Take unit out of service immediately and contact Chromalox to schedule service.

Fan Motor bearings are permanently lubricated and do not require maintenance

Preventative Maintenance Recommendations

Frequency

1

2

Action

Using compressed air, clean off motor, fan, heat exchanger, louvers, and interior of heater case.

Check relief valve and heat exchanger welds for leaks or cracks. If leakage or cracks has occurred, replace heat exchanger immediately.

3

Check motor for smooth operation.

Annually Monthly Every 3 Months Every 6 Months

X

X

X

X

X

X

4

Check enclosure covers and conduit / cable con-

5

6

7

Inspect enclosures for debris or foreign material, that could potentially cause shorting.

Inspect all electrical wiring and connections, including terminals, crimps, and wire insulation. Feel for loose connections and look for signs of loose connections, such as discoloration of terminals or wire insulation.

Check heating element resistance and insulation resistance (MegOhm). See document PF506 for more information.

X

X

X

X

X

X

X

© 2020 Chromalox,

8. Repair and Replacement

© 2020 Chromalox,

8. Repair and Replacement Cont.

Replacing Motor and/or Fan Blade

1. Disconnect the unit from power supply.

2. (Units with motor splice box) Remove 4 bolts and cover of motor splice box

3. (See Figure 12). (Units without motor splice box) Remove 16 bolts and cover of main control enclosure.

4.

Note wire connections for future reference and disconnect all wires leading to the motor. All motor wires are permanently marked according to the nameplate on the motor.

5.

Remove 4 bolts in motor base holding it to rear cabinet shelf.

6.

Remove 4 screws holding fan guard to cabinet.

7.

Unthread union at motor wiring outlet nipple connection. Carefully lift the motor, fan blade, and guard off of the cabinet.

8.

Note position of fan blade on motor shaft. Loosen the two set screws to remove the fan blade and key from shaft motor.

9.

Place guard and fan blade on replacement motor shaft in same locations as original motor. Align key ways in hub and shaft. Insert key flush with fan hub and tighten the two hub set screws.

10.

Feed motor wires back into conduit and reposition motor back on unit. Center fan blade in opening and rotate to be sure that it clears housing and guard.

11.

Thread motor nipple connection into conduit union and tighten (5 threads minimum). Replace bolts in motor base and reattach fan guard to back of housing in four places. Recheck blade rotation and tighten all hardware.

12.

Trim all motor leads extending out of the conduit to 6 lengths. Strip off 3/8 of insulation at cut ends. Using the motor nameplate, previous notes, and marked wires, reconnect the motor for the unit voltage rating as indicated on the heater nameplate. Re attach the ground wire to the connection inside the enclosure.

Replace cover and tighten securely.

13.

Check fan rotation by momentarily energizing the unit.

Air must exit at cabinet front. Reverse any 2 leads at contactor or line supply disconnect to reverse rotation of three phase motor.

14.

Removal of fan blade does not require that the motor wiring be disturbed. To clean, service or change the fan blade proceed as follows:

A. Remove the four carriage bolts holding the motor base in place on the cabinet platform. Mark the platform to reposition at same location.

B. Loosen the four screws on the cabinet back holding the fan guard in place.

C. Pull the motor to the rear extending the conduit connection at the electrical enclosure. Fan blade and hub set screws can now be accessed by tilting the guard rearward at top or bottom back over the motor shell.

Motor Bolt Removal

Motor Splice Box

© 2020 Chromalox,

8. Repair and Replacement Cont.

Flameproof Enclosures

1. Do not attempt to repair any flameproof enclosures joints. If joints or flame paths appear to be damaged contact Chromalox immediately for replacement.

2. If threaded cover bolts or screws are damaged, they must only be replaced with factory provided fasteners.

3. When securing enclosure bolts or screws, hand tighten and follow table E for proper torque spec.

Table E - Flameproof Enclosure Bolt Torque

Enclosure

Control Enclosure

Thermostat Enclosure

Heating Element Terminal Housing

Bolt Size

7/16 14 UNC 2A

5/16 18 UNC 2A

N/A

Bolt Grade

SAE 8

SAE 7

N/A

Bolt Torque

(ft lbs)

52

18

N/A

Bolt Torque

(N M)

70.5

24.4

N/A

© 2020 Chromalox,

8. Repair and Replacement Cont.

Replacing Contactor, Transformer, and Pilot Lights



To access electrical components, remove cover of main control enclosure. Remember to follow all guidelines regarding electrical safety in hazardous locations.



Before disconnecting any wires, note the wiring configuration and connections to terminal blocks and other equipment.



Contactor and transformer use retaining screws attached to a panel plate within enclosure. Once the wires are disconnected, the components can be removed by loosening screws holding them to the mounting plate.



To remove pilot lights, unscrew them from the enclosure once wires are disconnected. Pilots lights are equipped with fusing.

Fuses must be replaced with equivalent rated models.



Only replace electrical components with those that are factory supplied and have an equivalent rating.

Fuse Block

© 2020 Chromalox,

8. Repair and Replacement Cont.

© 2020 Chromalox,

9. Troubleshooting

Condition Probable Cause

Motor has overheated

Corrective Action

Wait 10 15 minutes for motor to cool down

Unit is not operating or stops operating

High limit cutout has tripped See condition "High limit cutout trips"

Fan is spinning but unit is not putting out heat

Heat exchanger has lost vacuum

Check for signs of vacuum loss, such as leaks near relief valve. If discovered, contact Chromalox and arrange for service.

Inlet or outlet are blocked Clean unit using compressed air

Heat exchanger is dirty

Failed heating element

Clean unit using compressed air

Contact Chromalox and arrange for service.

Motor may not be spinning at rated rpm Check motor winding resistance

High limit cutout trips or cycles

Heat exchanger has lost vacuum

Check for signs of vacuum loss, such as leaks near relief valve. If discovered, contact Chromalox and arrange for service.

Inlet or outlet are blocked Clean unit using compressed air

Heat exchanger is dirty

Relief valve has activated Unit has overheated

Clean unit using compressed air

Contact Chromalox and arrange for service.

Fuse or GFI blows Short in wiring

Failed heating element

Check all wiring for loose or frayed connections and tighten or replace

Contact Chromalox and arrange for service.

Large vibration or strange noise coming from heater

Fan motor is unbalanced

Check to see if set screw is loose. If loose, tighten set screw and ensure fan blade is balanced.

Contactor is chattering (turning on/off rapidly)

Contactor is defective or loose connections / short in wiring

Check for burn marks on the contactor terminals and look for frayed or loose wires. Replace contactor.

Note: Chromalox document PF506 provides additional information regarding troubleshooting.

© 2020 Chromalox,

© 2020 Chromalox, to

Chromalox, Inc.

103 Gamma Drive

Pittsburgh, PA 15215

.chromalox.com

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