Chromalox DH Manual de usuario

Installation Instructions

DH and DHOC

Electric Duct Heaters

PF503

161-562766-001

February 2015

Table of Contents

Section Page

General ...............................................................................................................................3

Installation..........................................................................................................................3

Mounting ............................................................................................................................6

Wiring................................................................................................................................10

Operation .........................................................................................................................11

Maintenance ....................................................................................................................11

Heater Bundle Removal and Replacement...................................................................11

Replacement Parts..........................................................................................................12

Troubleshooting...............................................................................................................13

DH and DHOC Electric Duct Heaters

Read and understand all instructions before in-

stalling, servicing or operating product. Failure

to do so could result in personal injury or prop-

erty damage.

These heaters are designed to be installed in either a

horizontal or vertical duct in one of the six positions

shown in ﬁgure 12. The heater is constructed with in-

dividual metal sheath ﬁntube elements mounted to a

heavy gauge metal terminal box.

Due to the various options and materials available,

check the nameplate attached to the heater terminal

box with the catalog number designation system be-

fore installing to insure the heater you received con-

forms to your speciﬁcation.

Please read these directions carefully to insure all limi-

tations are properly observed and all wiring and con-

trols are properly installed and connected.

IMPORTANT - Observe at least one complete heat-

ing cycle operation before leaving the installation.

FIRE/EXPLOSION HAZARD. This heater is not

intended for use in hazardous atmospheres

where ﬂammable vapors, gases, liquids or

other combustible atmospheres are present as

deﬁned in the National Electrical Code. Failure

to comply can result in personal injury or prop-

erty damage.

ELECTRIC SHOCK HAZARD. Any installation

involving electric heaters must be performed

by a qualiﬁed person and must be effective-

ly grounded in accordance with the National

Electrical Code to eliminate shock hazard.

ELECTRIC SHOCK HAZARD. Disconnect all

power before installing or servicing heater.

Failure to do so could result in personal injury

or property damage. Heater must be installed

or serviced by a qualiﬁed person in accordance

with the National Electrical Code, NFPA 70.

Limitations: Must be in accordance with one of the

following: Standards of the National Fire Protection

Association for the installation of Air Conditioning and

Ventilating Systems of other than Resident Type (Pam-

phlet 90A) or Residential Type Warm Air Heating and

Air Conditioning Systems (Pamphlet 90B).

NOTE: The minimum distances shown are limitations.

Wherever possible, locate as far away from these lim-

its as practical. In any case, this distance with any re-

quired airﬂow correction must be sufﬁcient to accom-

plish even air ﬂow at a velocity equal to, at least, the

minimum stated on the heater nameplate.

1. Installation near heat pump, central air conditioner,

ﬁlters or humidiﬁer. (Refer to Figure 1).

Duct Heater

4 Ft.

Min.

Heat Pump,

Central Air Conditioner,

Filters or Humidifier

Air

Flow

Figure 1

General

Installation

Installation near air handler discharge. (Refer to Fig. 2).

Duct Heater

4 Ft.

Min.

Air Handler

Air

Flow

Figure 2

3. Installation in branch duct take-off. (Refer to Fig. 3).

Duct Heater

4 Ft. Min. Straight Section

Air Flow

Figure 3

Installation near turns. (Refer to Fig. 4). If heater must

be installed closer than 4 feet from the downstream

side of a turn, turning vanes must be installed in the

turn. The turning vanes will straighten out the air

ﬂow so it will be uniform over the face of the heater.

4 Ft.

Min.

Duct Heater

Here or Here

2 Ft.

Min.

Air Flow

Figure 4

5. Installation with duct transitions in some air distri-

bution systems, the duct heater may be consid-

erably larger than the ductwork and the duct area

must be increased by a sheet metal transition. The

slope of the transformation piece on the upstream

side of the equipment is limited to 30° as indicated

in Fig. 5. On the leaving side, the slope should not

be more than 45°.

Air

Flow

30"

Max. 45°

45°

30°

4 Ft. Min. 4 Ft. Min.

Max.

Duct Heater

Figure 5

Do not insulate control or terminal box. (Refer to Fig. 6).

Figure 6

Leave Control

Box Uninsulated

External

Insulation

Top of Duct Duct Heater

7. Installation in duct larger than heater. For installa-

tion where the duct dimensions exceed the insert

type heater dimensions, the area beyond the heater

dimensions must be ﬁlled with wire mesh, expand-

ed or perforated sheet metal of 50% open area as

shown in Figure 7. This will maintain a uniform air

velocity across the face of the duct.

Inner Baffle Insert Type

Duct Heater

Remove Bracket and

Use Sheetmetal Screws

Thru Same Holes into Duct.

Oversized Duct

Perforated Metal

(50% Open Area)

Figure 7

8. Installation with ﬂexible duct. Where a duct heater

must be installed near a ﬂexible duct connection,

be certain that a 4’ minimum distance between the

duct heater and the ﬂexible connector exists and

that the connector is suitable for 195°F tempera-

ture. (Refer to Fig. 8).

9. Do not install duct heater outdoors. Duct heaters

cannot be installed with rooftop equipment where

they are exposed to the weather.

4 Ft.

Min.

Air

Flow

Duct Heater

Flexible Duct

(Must be suitable

for 195°F)

Figure 8

10.

Installation with dampers or ﬁlters. Maintain at least

4’ distance between duct heater and damper, ﬁlter

frames, or other similar obstructions. (Refer to Fig. 9).

4 Ft.

Min.

Damper Air Flow

Top of Duct

Duct

Heater

Figure 9

Clearance: Zero clearance between duct heater and

combustible materials such as wood is permissible.

However, adequate clearance must be provided around

terminal box for proper ventilation and future service ac-

cessibility.

Example: 500 FT./MIN. Minimum Air Velocity

on Heater Nameplate.

Velocity

Proﬁle

Ft./Min.

600

Velocity

Proﬁle

Ft./Min.

200x

500 400x

700 800

600 900

900 600

700 700

600 200x

500 300x

400x

RIGHT: 500 Ft./Min.

Minimum WRONG:

9 4500 =

500 Ft./Min

Average

Multiple Duct Heaters: Up to six duct heaters may be

combined into a heating bank as shown in Figure 11.

When called for on order, brackets will be furnished for

fastening ﬂange type duct heaters together to form a

bank. Heater will be coded for proper assembly in the

ﬁeld.

Two to six duct heaters (with ﬂange) may be installed in

a horizontal or vertical duct.

Heaters must be mounted in the position designated

by arrows on the heater frame. (Refer to Figure 12).

The heater terminal box on vertical duct installations

can be located on any side of the duct but for horizon-

tal duct installation the terminal box must be on the

side of the duct.

Mounting

Figure 11

Flow through duct heater must never drop below the

minimum air velocity shown on duct heater nameplate.

If the air handling system includes ﬁlters, they must be

cleaned whenever necessary in order to maintain air

ﬂow above the minimum, otherwise poor temperature

control and discomfort will result.

If air ﬂow is poorly distributed within the duct, deﬂector

vanes must be added to provide correction.

The minimum air velocities shown on the nameplate

are not to be considered average readings. Do not add

various velocities taken across the face of the duct,

ﬁnd an average value, and compare it to the minimum

velocity shown on the heater nameplate.

The minimum air velocity refers to any point along the

face of the duct heater when checking duct velocities,

no velocity can be below that sown on the heater name-

plate (remembering inlet air temperature). Velocities are

best checked with an anemometer, taking numerous

readings along the horizontal and vertical centerline

of the duct heater at the location prior to installation

or slightly up stream from the heater after installation.

(Refer to Figure 10). Large ducts will require additional

readings taken at locations in addition to the centerline.

Figure 10

Duct Heater

Velocity

Profile

Air Flow

Incoming Air Temperature: Incoming air temperature

entering the duct heater must not exceed 100°F.

Air Flow

Horizontal duct with panel

extended in left direction

Bottom mount in horizontal duct with

panel extended in RIGHT direction

Vertical duct with panel extended

in DOWNWARD direction

Vertical duct with panel extended

in Upward direction

Horizontal duct with panel extended

in RIGHT direction

Bottom mount in horizontal duct with

panel extended in LEFT direction

Figure 12

Airflow

Left

Airflow

Right

Airflow

Down

Airflow

Left

Airflow

Right

Airflow

Left

Airflow

Right

Airflow

Down

Airflow

Left

Airflow

Right

Mounting Procedure

(Flanged heaters with control box)

1. At heater location, cut out a section of duct, or a

new construction lay out duct work to accommo-

date dimensions of heater.

2. Form mounting ﬂanges on cut edges of duct as

shown in Figure 13. Omit ﬂange in side when termi-

nal box overhangs.

3. Position heater in duct and attach duct lip to heater

ﬂanges with sheet metal screws.

4. Attach control box to duct with sheet metal screws

through the mounting holes provided inside the

control box.

NOTE: Where necessary, make provision to support

weight of heater. Any part of heater ﬂange may be

drilled for attaching hanger straps or duct.

5. Where necessary, joint between duct and heater

ﬂange may be sealed with silicone gaskets or sili-

cone sealant.

Mounting Procedure

(Insert heaters with control box)

NOTE: Insert or slip-in type duct heaters are designed

to be inserted into existing duct and require a rectan-

gular hole of proper size to be cut. The heater frame is

manufactured with a speciﬁed duct height (H in ﬁgure

14) and a standard depth (D in ﬁgure 14). If the frame

does not match the speciﬁed dimensions contact a

Chromalox representative.

1. Measure the height and width of the heater frame

and note (H and D per ﬁgure 14).

2. The next step is to cut out the rough opening. Cut a

rectangle in the duct with dimensions H x (D - 1.5”).

Remove the sheet metal. (See ﬁgure 14A)

3. With the rough opening cut and the sheet metal re-

moved, cut the remaining 3/4 and fold over sides to

create support tabs. (See ﬁgure 14A).

4. Attach control box to duct with sheet metal screws

through the mounting holes provided inside the

control box and through the brackets on the top

and bottom of heater.

5. Where necessary, make provision to support weight

of heater and terminal box.

Mounting

Self-Adhesive Gasket

Supplied with Heater and

Installed by Customer

Double

Lip

3/4"

3/4" Duct

Sheet Metal

Screws

Control

Box

Sheet Metal

Screws

Mounting

Holes W

Figure 13

Self-Adhesive Gasket

Supplied with Heater and

Installed by Customer

Double

Lip

3/4"

Duct

Control

Box

Sheet Metal

Screws

Mounting

Holes W

Figure 14

Cut 3/4” and fold

over to create tab

Cut 3/4” and fold

over to create tab

Cut out and remove

shaded area H x (D-1.5”)

Figure 14a

Mounting Procedure

(Flanged heaters with compact terminal box)

1. At heater location, cut out a section of duct, or on

new construction lay out duct work to accommo-

date dimensions of heater.

2. Form mounting ﬂanges on cut edges of duct as

shown in Figure 15.

3. Position heater in duct and attach duct lip to heater

ﬂanges with sheet metal screws.

NOTE: Where necessary, make provision to support

weight of heater. Any part of heater ﬂange may be

drilled for attaching hanger straps or duct.

4. Attach control box to duct with sheet metal screws

through the mounting holes provided inside the

control box.

5. Where necessary, joint between duct and heater

ﬂange may be sealed with silicone gasket or seal-

ant.

Mounting Procedure

(Insert heaters with compact terminal box)

NOTE: Insert or slip-in type duct heaters are designed

to be inserted into existing duct and require a rectan-

gular hole of proper size to be cut. The heater frame is

manufactured with a speciﬁed duct height (H in ﬁgure

16) and a standard depth (D in ﬁgure 16). If the frame

does not match the speciﬁed dimensions contact a

Chromalox representative.

1. Measure the height and width of the heater frame

and note (H and D per ﬁgure 16).

2. The next step is to cut out the rough opening. Cut a

rectangle in the duct with dimensions H x (D - 1.5”).

Remove the sheet metal. (See ﬁgure 16A)

3. With the rough opening cut and the sheet metal re-

moved, cut the remaining 3/4 and fold over sides to

create support tabs. (See ﬁgure 16A).

4. Attach control box to duct with sheet metal screws

through the mounting holes provided inside the

control box and through the brackets on the top

and bottom of heater.

5. Where necessary, make provision to support weight

of heater and terminal box.

Figure 15

Self-Adhesive Gasket

Supplied with Heater and

Installed by Customer

Double

Lip

3/4"

Duct

Sheet Metal

Screws

Mounting

Holes W

Figure 16

Self-Adhesive Gasket

Supplied with Heater and

Installed by Customer

Double

Lip

3/4"

3/4" Duct

Sheet Metal

Screws

Sheet Metal

Screws

Mounting

Holes W

Cut 3/4” and fold

over to create tab

Cut 3/4” and fold

over to create tab

Cut out and remove

shaded area H x (D-1.5”)

Figure 16a

ELECTRIC SHOCK HAZARD. Disconnect all

power before installing or servicing heater.

Failure to do so could result in personal injury

or property damage. Heater must be installed

or serviced by a qualiﬁed person in accordance

with the National Electrical Code, NFPA 70.

ELECTRIC SHOCK HAZARD. Any installation

involving electric heaters must be performed

by a qualiﬁed person and must be effective-

ly grounded in accordance with the National

Electrical Code to eliminate shock hazard.

1. Connect heater only to the voltage, frequency and

phase speciﬁed on the nameplate.

2. All wiring should be done according to local and

National Electric Codes.

3. Make supply connections to marked heater termi-

nals using wire suitable for 75°C. (Type RH-RW or

equivalent). In addition, the supply wires must be

rated to supply a minimum of 125% of the total am-

perage load required by the Duct Heater.

4. Connect ﬁeld wiring to the Duct Heater using the

Wiring Diagram provided with the heater.

5. Conduit attachment to heater:

a. Ensure that conduit size used matches the

knock-out size(s) provided on Duct Heater

b. Run conduit(s) to conduit knock-out(s) on Duct

Heater

c. Remove knock-out(s) with a punch and hammer.

d. Install conduit to knock-out hole.

6. If the heater does not include a main circuit breaker

or a disconnect switch, a remote disconnect must

be provided (see N.E.C. 424.65).

7. Any wiring that is connected to the secondary

(control) wiring of the Duct Heater is required to be

N.E.C. class 1 (see National Electric Code, Article

725).

Wiring Diagram

The appropriate wiring diagram will be supplied with

each heater.

Wiring

Field Wire/Conduit Sizing (based on 125% of total heater amperage)

1PH 3PH Wire Size

(AWG or

kcmil)

Conduit Size

Heater

Amps120 208 240 277 208 240 480 1ph 3ph

1.4 2.5 2.9 3.3 4.3 5.0 10.0 14 1/2 1/2 12

1.8 3.1 3.6 4.2 5.4 6.2 12.5 12 1/2 1/2 15

2.5 4.4 5.0 5.8 7.6 8.7 17.5 10 1/2 1/2 21

3.8 6.7 7.7 8.9 11.5 13.3 26.6 8 1/2 3/4 32

4.7 8.1 9.4 10.8 14.1 16.2 32.4 6 3/4 3/4 39

6.1 10.6 12.2 14.1 18.4 21.2 42.4 4 3/4 1 51

7.2 12.5 14.4 16.6 21.6 24.9 49.9 3 1 1 60

8.3 14.4 16.6 19.1 24.9 28.7 57.4 2 1 1-1/4 69

9.4 16.2 18.7 21.6 28.1 32.4 64.8 1 1-1/4 1-1/4 78

10.8 18.7 21.6 24.9 32.4 37.4 74.8 1/0 1-1/4 1-1/2 90

12.6 21.8 25.2 29.1 37.8 43.6 87.3 2/0 1-1/4 1-1/2 105

14.4 25.0 28.8 33.2 43.2 49.9 99.8 3/0 1-1/2 2 120

16.6 28.7 33.1 38.2 49.7 57.4 114.7 4/0 2 2 138

18.4 31.8 36.7 42.4 55.1 63.6 127.2 250 2 2-1/2 153

20.5 35.6 41.0 47.4 61.6 71.1 142.2 300 2 2-1/2 171

22.3 38.7 44.6 51.5 67.0 77.3 154.6 350 2-1/2 2-1/2 186

24.1 41.8 48.2 55.7 72.4 83.6 167.1 400 2-1/2 3 201

27.4 47.4 54.7 63.2 82.1 94.8 189.6 500 2-1/2 3 228

30.2 52.4 60.5 69.8 90.8 104.8 209.5 600 3 3-1/2 252

33.1 57.4 66.2 76.5 99.4 114.7 229.5 700 3 3-1/2 276

35.3 61.2 70.6 81.4 105.9 122.2 244.4 800 3 3-1/2 294

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