Thermon Caloritech GE Series Instrucciones de instalación

ISO 9001

GE heater with optional disconnect

Part No.MI153.Rev.5.07 August 2022 Printed in Canada

Regular Duty Forced Air Unit Heaters

GE 20 3 C T - D

Model

Series

Kilowatts

02 - 2 kW

03 - 3 kW

04 - 4 kW

05 - 5 kW

07 - 7.5 kW

10 - 10 kW

15 - 15 kW

20 - 20 kW

25 - 25 kW

30 - 30 kW

Voltage

2 - 208

3 - 240

5 - 347

6 - 416

7 - 480

8 - 600

Contactor

(Optional)

Thermostat

(Optional)

Other Options

B - Epoxy painted fan blade and motor

D - Disconnect switch

F - Fan switch

K - Fused control circuit

L - Energy Management Controller

M - Manual reset high limit

N - Low voltage relay (24V)

V - 120V control voltage (240V is standard)

Model Coding

C US

Caloritech™ is a registered trademark of Thermon.

Installation & Operation Instructions

GE Series

IMPORTANT INSTRUCTIONS - SAVE THESE INSTRUCTIONS

Read all instructions before installing or using the heater. Please adhere to instructions

published in this manual. Failure to do so may be dangerous and may void certain

provisions of your warranty.

TABLE OF CONTENTS

A. Important Notices 3

B. Installation 3

B.1 Location................................................................................................................................................. 3

B.2 Mounting ............................................................................................................................................. 4

B.3 Electrical................................................................................................................................................5

B.4 Sample Wiring Schematics GE Series Heaters......................................................... 5

C. Operation 8

C.1 General ...................................................................................................................................................8

D. Repair & Replacement 8

D.1 Heating Elements...........................................................................................................................8

D.2 Fan ...........................................................................................................................................................8

D.3 Thermal Cut-Out............................................................................................................................8

E. Parts List 9

F. Troubleshooting Tips 11

F.1 Heater is not operating................................................................................................................11

F.2 Contactor is chattering...............................................................................................................11

F.3 Contactor is burned or welded.............................................................................................11

F.4 Heater cycles on high limit......................................................................................................11

F.5 Heater is operating but no heat is present...................................................................11

F.6 Heater fan does not operate but the heating elements operate.................11

F.7 The Ground Fault Interrupter (GFI) trips on the main panel, or heater

blows fuses..........................................................................................................................................11

F.8 The fan is turning but very little air comes from the front of the heater.11

G. Technical Data 12

H. General Specifications 13

I. Heater Maintenance Checklist 14

I.1 Periodic (before and as required during heating season) .............................14

I.2 Annual (before heating season)......................................................................................14

Important Notices

A. IMPORTANT NOTICES

CAUTION

CAUTION. This symbol indicates a potentially hazardous

situation, which, if not avoided, may result in personal

injury or damage to the equipment.

WARNING

WARNING. This symbol indicates an imminently

hazardous situation, which, if not avoided, can result in

serious injury or damage to the equipment.

WARNING

WARNING. Read and adhere to the following. Failure to

do so may result in a risk of re, electrical shock, and

severe or fatal injury. Warranty will be void.

1. Read and follow all instructions in this manual.

2. Appropriate protection against ground faults, such as a

ground-fault circuit interrupter or GFCI, is required to be

used with this equipment. Failure to provide protection

against electrical grounding or bonding during the use of

this equipment can result in property damage, personal

injury, or death. In addition, this equipment must be

effectively grounded in compliance with all applicable

electrical codes and standards

3. This heater is intended to be used for commercial and

industrial indoor space heating applications.

WARNING

WARNING. Heater is not to be used in hazardous

atmospheres where ammable vapors, gases, liquids or

other combustible atmospheres are present.

4. Heater is to be connected and serviced only by a qualied

electrician.

5. Installation and wiring of the heater must adhere to all

applicable codes.

6. Disconnect heater from power supply at disconnect or

fuse box before opening enclosures or servicing heater. IF

DISCONNECT IS BEING SERVICED, verify power has been

disconnected at fuse box or main panel. Lock the switch

in the “OFF” (open) position and tag the switch to prevent

unexpected power application.

7. Do not operate heater in wet and humid environments.

WARNING

WARNING. Elements get hot during operation.

Contact can cause burns.

8. Install and maintain clearances as per this manual.

9. Do not operate the heater in corrosive atmospheres.

10. Use factory replacement parts only.

11. Maximum ambient operating temperature is 40°C (104°F).

12. Do not operate the heater with the louvers deformed

or damaged.

13. If there are any questions or concerns regarding the

heater, please refer to contact information on the back

page of this manual.

14. Follow the recommended maintenance procedures under

Section I. Heater Maintenance Instructions, page 16.

B. INSTALLATION

All applicable codes must be adhered to. For optimum

performance, the heater should be installed as follows:

B.1 Location

1. Ensure there are no obstructions that may impede

the heater’s air inlet or discharge. Refer to Figure 1 and

Figure2, page4, for minimum clearances.

2. Ensure the air discharge is not directed at a thermostat.

3. Ensure the air discharge is not directed towards areas of

heat loss, such as windows.

4. Ensure the air discharge is directed along and at a slight

angle toward exterior walls.

5. If equipment freeze protection is important, direct air

discharge at equipment while maintaining minimum

clearances.

Installation

WALL MOUNT

WITH CLEARANCES

FRONT VIEW

REAR VIEW

2¼"

HEATING ELEMENTS

MOTOR

1/2" x 3/4" MULTIPLE

CONDUIT ENTRY

1" x 1-1/4" MULTIPLE

CONDUIT ENTRY

MIN. INLET

WALL MOUNT

BRACKET HOLE

PATTERN

CLEARANCE

6 FT C

MOUNTING ARM

MIN.

DISCHARGE

DISTANCE

'R' HOLE

CEILING MOUNT

WITH CLEARANCES

'W' HOLE

6" MIN.

CEILING

CLEARANCE

WALL MOUNT

WITH CLEARANCES

FRONT VIEW

REAR VIEW

2¼"

HEATING ELEMENTS

MOTOR

1/2" x 3/4" MULTIPLE

CONDUIT ENTRY

1" x 1-1/4" MULTIPLE

CONDUIT ENTRY

MIN. INLET

WALL MOUNT

BRACKET HOLE

PATTERN

CLEARANCE

6 FT C

MOUNTING ARM

MIN.

DISCHARGE

DISTANCE

'R' HOLE

CEILING MOUNT

WITH CLEARANCES

'W' HOLE

6" MIN.

CEILING

CLEARANCE

Table1 – Heater & Bracket Dimensions

Dim. 2-10 kW 15 – 30 kW

in. mm in. mm

A17 432 24 610

B 14 356 19 1/2 495

C (Depth) 15 1/2 394 22 559

R (Hole dia.) 1/2 13 5/8 16

S 12 1/2 318 17 1/2 445

T 4 1/2 114 6 152

U 4 1/2 114 6 152

W (Hole dia.) 3/4 19 3/4 19

Figure 1

Figure2 – Mounting Clearance

FRONT VIEW REAR VIEW

2¼"

HEATING ELEMENTS

MOTOR

1/2" x 3/4" MULTIPLE

CONDUIT ENTRY

1" x 1-1/4" MULTIPLE

CONDUIT ENTRY

WALL MOUNT

BRACKET HOLE

PATTERN

'D' HOLE

CEILING MOUNT

WITH CLEARANCES

'W' HOLE

6” (152mm) MIN.

CEILING

CLEARNACE

WALL MOUNT

WITH CLEARANCES

3.5" (89 mm) for 2 to 10 kW

6.0” (152 mm) for 15 to 30 kW

MINIMUM WALL CLEARANCE

72”

(1830 mm)

DISCHARGE

DISTANCE

MOUNTING ARM

72”

(1830 mm)

MINIMUM

WALL MOUNT

WITH CLEARANCES

FRONT VIEW REAR VIEW

2¼"

HEATING ELEMENTS

MOTOR

1/2" x 3/4" MULTIPLE

CONDUIT ENTRY

1" x 1-1/4" MULTIPLE

CONDUIT ENTRY

MIN. INLET

WALL MOUNT

BRACKET HOLE

PATTERN

CLEARANCE

6 FT C

MOUNTING ARM

MIN.

DISCHARGE

DISTANCE

'R' HOLE

CEILING MOUNT

WITH CLEARANCES

'W' HOLE

6" MIN.

CEILING

CLEARANCE

FRONT VIEW REAR VIEW

2¼"

HEATING ELEMENTS

MOTOR

1/2" x 3/4" MULTIPLE

CONDUIT ENTRY

1" x 1-1/4" MULTIPLE

CONDUIT ENTRY

WALL MOUNT

BRACKET HOLE

PATTERN

'D' HOLE

CEILING MOUNT

WITH CLEARANCES

'W' HOLE

6” (152mm) MIN.

CEILING

CLEARNACE

WALL MOUNT

WITH CLEARANCES

3.5" (89 mm) for 2 to 10 kW

6.0” (152 mm) for 15 to 30 kW

MINIMUM WALL CLEARANCE

72”

(1830 mm)

DISCHARGE

DISTANCE

MOUNTING ARM

72”

(1830 mm)

MINIMUM

B.2 Mounting

1. The heater must be permanently mounted to a xed

location onto a wall or ceiling.

2. The mounting surface must be strong enough to:

–Support the heater’s weight.

–Provide sufcient stiffness to prevent excessive

vibration.

3. The single bolt mounting is not designed for high dynamic

loads that can occur during transportation. For heaters

that are to be installed prior to transportation, it is

recommended that temporary blocking or strapping be

used to limit movement of the heater with respect to the

mounting structure. Inspection of the mounting bolt for

correct tensioning is also recommended after arrival at site

to ensure no loosening has occurred in transportation. The

mounting bolt/nut should be torqued to 65 – 75ft-lbs, refer

to Table5, page11.

4. Install the bracket on the heater with hardware provided.

4.1 Orient the heater to its nal position before

tightening all hardware.

4.2 In higher vibration installations use of a removable

thread locking compound such as Loctite® 243™

Blue Threadlocker is recommended.

4.3 Correct tensioning of the mounting bolt will include

full compression of the split lock washer and

inspection for correct thread engagement. The

mounting bolt/nut should be torqued to 65 – 75ft-lbs,

refer to Table5, page11.

5. The discharge air louvers are individually adjustable.

(57 mm)

72”

(1830 mm)

MINIMUM

Table2 – Installation Height & Heater Weight

kW Recommended Mounting

Height - ft (m)

Heater Weight

lbs (kg)

2 – 10 6 to 8 (1.8 to 2.4) 53 (24)

15 – 3 0 8 to 12 (2.4 to 3.6) 104 (47)

WARNING

WARNING. Install heater with suffcient clearance to walls

and ceiling as indicated in gure 2 on page 4. Mount with

bottom of heater no less than 6 ft (1830 mm) above oor

or grade.

Installation

B.3 Electrical

WARNING

WARNING. Disconnect heater from power supply at

disconnect or fuse box before opening enclosures or

servicing heater.

Lock the switch in the “OFF” (open) position and tag the

switch to prevent unexpected power application.

This heater should only be serviced by qualied personnel

with electrical heating equipment experience.

Install and use the heater in accordance with local codes

and this manual.

1. General

1.1 Use only approved copper conductors for

installation. Refer to Section G. Technical Data, page

12 and heater data plate for heater rating.

1.2 The power supply may be single or three phase as

shown on the nameplate. Wiring diagrams are on

the inside of the terminal compartment cover (or

refer to B.3.7, page5). Connection box volume:

2 to 10kW: 9,893 cm³, 15 to 30 kW: 32,333 cm³.

2. Field Wiring

Heater is supplied with an enclosure that has standard

trade size conduit openings to accommodate the line

conductors or external thermostat connection. Two 1/2" or

3/4" conduit knockouts are located on the 2 to 10 kW units.

Two 1/2", 3/4", 1" or 1-1/4" conduit knockouts are located on

the 15 TO 30 kW units.

3. Heater may be supplied with a factory-installed built-in

room thermostat. On heaters not supplied with this option,

a remote thermostat is required. Connect the remote

thermostat conductors to the terminal block, refer to

Section 7. Sample Wiring Schematics - GE Series Heater,

page 5 – 7. Remote thermostats are available from

the factory. Any thermostat used with this heater must be:

3.1 UL listed or CSA approved

3.2 Rated for 240 volts minimum and 5 amps minimum.

4. Grounding: a copper compression terminal is located

beside the terminal block. Ensure the unit is properly

grounded before energizing.

5. Models without a built-in contactor should have the limit switch

wired in the control circuit of an external contactor, and for

three phase supply, this control circuit should be connected

to L2 and L3 which feed the centre heating element,

refer to

Figure3E, page 7.

The limit switch is rated 600 volts, 10

amps

resistive.

6. Final Inspection

Before application of electrical power:

6.1 Check that all connections are secured and comply

with the applicable code requirements.

6.2 Conrm supply voltage is compatible with the data

plate specications.

6.3 Remove any foreign objects from the heater.

6.4 Ensure all external ttings and enclosure covers are

secured.

6.5 Ensure fan rotates freely.

6.6 If equipped, ensure manual reset thermal cut-out

has been reset.

7. Sample Wiring Schematics - GE Series Heater

If the wiring schematics of Figures 3A – 3G, page5 – 7,

do not match your conguration, check the inside

access panel of the unit for specic wiring schematic.

Alternatively, all wiring schematics are available online at:

www.thermon.com.

B.4 Sample Wiring Schematics GE Series Heaters

Figure 3A – GE Series 2 – 10 kW wiring schematic with hi-limit option. 208V and 240V models.

Installation

Figure 3B – GE Series 2 – 10 kW wiring schematic with hi-limit and fused control circuit options. 208/240/480/600V models.

Figure 3C – GE Series 2 – 10 kW wiring schematic with hi-limit, contactor, built-in thermostat, fan only switch options. 208 - 240V models.

Figure 3D – GE Series 2 – 10 kW wiring schematic with hi-limit, contactor, built-in thermostat, fan only switch, transformer and fused control

circuit options. 208 – 600V models.

B.4 Sample Wiring Schematics GE Series Heaters (cont’d)

If the wiring schematics of Figures 3A – 3G, page5 –7, do not match your conguration, check the inside access panel of the

unit for specic wiring schematic.

Installation

B.4 Sample Wiring Schematics GE Series Heaters (cont’d)

Figure3E - GE Series 15 – 30 kW wiring schematic with hi-limit option. 208 – 600V models.

Figure 3F - GE Series 15 – 30 kW wiring schematic with hi-limit and contactor options. 208 – 240V models.

Figure 3G - GE Series 15 – 30 kW wiring schematic with hi-limit, contactor, transformer and fused control circuit options. 208 – 600V models.

Operation, Repair & Replacement

C. OPERATION

C.1 General

1. To operate heater, ensure power supply is properly

connected as specied in the wiring schematic (refer to

Figures 3A – 3G, page5 – 7).

2. If the heater is setup to operate on a thermostat, ensure

the temperature set point is set high enough to turn on

the heater

3. During normal operation, the thermal cut-out control should

not cycle the heater ON and OFF. If cycling occurs, check to

see if there is an airow blockage. If there are no obstructions,

the heater must be examined by qualied personnel to

determine the cause of the thermal cut-out cycling.

4. Operate the unit for a minimum of 10 minutes to allow the

heating elements to reach a steady state. If no warm air

is discharged from the heater, shut off the unit and see

Section F. Troubleshooting Tips, page 11.

D. REPAIR & REPLACEMENT

WARNING

WARNING. Disconnect heater from power supply at

disconnect or fuse box before opening enclosures or

servicing heater.

Lock the switch in the “OFF” (open) position and tag the

switch to prevent unexpected power application.

This heater should only be serviced by qualied personnel

with electrical heating equipment experience.

Install and use the heater in accordance with local codes

and this manual.

Note*: ONLY USE FACTORY SUPPLIED REPLACEMENT PARTS OF THE

SAME SPECIFICATION. REFER TO TABLE3, PAGE10 FOR

COMPLETE LISTING OF AVAILABLE PARTS.

D.1 Heating Elements

1. Disconnect all wires connected to the heating element

terminals. Remove louver assembly from heater. Remove

heating elements, noting their proper placement.

2. Install factory-supplied replacement heating element (see

Table3, page10 for Parts List).

2.1 Ensure heating element attaching screws are in

good condition.

2.2 Re-attach heating element mounting screws and

tighten.

2.3 Check heating elements are not in contact with the

cabinet or each other.

3. Reinstall all wires with hardware provided. Torque the

element terminal hardware to the torque specications,

refer to Table4, page11.

4. Reinstall the louvers.

D.2 Fan

1. Remove the rear grille. Remove the motor mount

assembly. Remove the screw securing the fan to the fan

hub attached to the motor.

2. Replace fan with factory-supplied fan. Install the fan such

that the mounting hub collar of the fan faces the inside of

the heater, i.e. facing towards the elements. Ensure motor

shaft end is ush to hub collar.

D.3 Thermal Cut-Out

1. Disconnect all wires connected to thermal cut-out.

2. Remove two mounting screws.

3. Remove thermal cut-out switch from the enclosure.

4. Replace thermal cut-out with factory-supplied

replacement thermal cut-out.

5. Reinstall thermal cut-out switch in the control enclosure.

6. Re-attach thermal cut-out mounting screws.

7. Reconnect all wires to thermal cut-out.

HEATER

CABINET

PANEL

ELEMENT

TERMINAL

HARDWARE

ELEMENT

MOUNTING

HARDWARE

HEATING ELEMENT

Figure4 – Heating Element Assembly

Parts List

BILL OF MATERIAL

ITEMDESCRIPTION

1 CABINET BOX ASSEMBLY

2LOUVER ASSEMBLY

3 MOTOR MOUNT

4MOTOR

5FAN BLADE

6COVER PANEL

7REAR GRILLE

8 NON-FINNED (2-10 KW), FINNED ELEMENT (15-40 KW)

9THERMOSTAT - SPST

10 THERMOSTAT KNOB

11 TRANSFORMER

12 THERMAL CUT-OUT

13 TERMINAL BLOCK, 6 POLE

14 TERMINAL BLOCK, 3 POLE

15 CONTACTOR, 3POLE

16 GROUND CONNECTOR

17 FUSE

18 HEATER COWL BAFFLE (GEA40 ONLY)

E. PARTS LIST

Item Description

1 Cabinet box assembly

2Louver assembly

3Motor mount

4Motor

5Fan blade

6Cover panel

7Rear grille

8Non-nned (2–10 kW),

Finned element (15–30 kW)

9 Thermostat - SPST

10 Thermostat knob

Figure5 – Parts Assembly Diagram & Chart

11 Transformer

12 Thermal cut-out

13 Terminal block, 6 pole

14 Terminal block, 3 pole

15 Contactor, 3 pole

16 Ground connector

17 Fuse

Parts List

Item Description VkW Part Number

1Cabinet box

assembly Contact Factory

2Louver assembly —2 – 10 B11022-01

15 – 3 0 B11022-02

3Motor mounting

Bracket —2 – 10 B11026-01

15 – 3 0 B11027-01

4Motor

208 2 – 10 B11041-02

15 – 3 0 B11059-02

240 2 – 10 B11041-02

15 – 3 0 B11059-02

480 2 – 10 B11041-02

15 – 3 0 B11059-03

600 2 – 10 B11041-02

15 – 3 0 B11059-04

5Fan blade —

2 – 5 C11028-02

7.5 C11028-03

10 C11028-04

15 C11028-05

20 C11028-06

25 – 30 C11028-07

6Cover panel —2 – 10 A11050-01

15 – 3 0 All049-01

7Rear grille —2 – 10 B11024-01

15 -30 B11023-01

Heating Elements

Non-nned

(2–10 kW)

Finned element

(15–30 kW)

208

2IXS11011-01

3IXS11011-05

4IXS11011-09

5IXS11011-13

7.5 IXS11011-18

10 IXS11011-23

15 KXF11008-81

20 KXF11008-84

25 KXF11008-33

240

2IXS11011-02

3IXS11011-06

4IXS11011-05

5IXS11011-14

7.5 IXS11011-19

10 IXS11011-24

15 KXF11008-82

20 KXF11008-85

480

4IXS11006-37

5IXS11006-16

7.5 IXS11006-21

10 IXS11006-26

15 KXF11008-64

20 KXF11008-62

25 KXF11008-35

30 KXF11008-61

600

4IXS11006-38

5IXS11006-17

7.5 IXS11006-22

10 IXS11006-27

15 KXF11008-83

20 KXF11008-86

25 KXF11008-36

30 KXF11008-65

Item Description VkW Part Number

9 Thermostat - SPST — 2 – 10 FAT 8

15-30

10 Thermostat knob —2 – 10 B11037-01

15-30

11 Transformer

240

2 – 10

TSK4114-32

480 B11033-02

600 B11033-03

480 15 -30 B11033-04

600 B11033-05

12 Thermal cut-out —2 – 10 B11035-03

15-30

13 Terminal block, 6

pole

Contact factory.

14 Terminal block, 3

pole

15 Contactor, 3 pole

16 Ground connector

17 Fuse

240

2 – 10

ATQR 1.4

480 ATQR 0.75

600 ATQR 0.75

208

15-30 ATQR 0.25

240

480

600

*Ceiling Bracket —— A11034-01

*Wall Bracket —2 – 10 WB 210

15 – 3 0 WB 1540

Note*: *Not shown in Figure 5

Table3 – Parts List

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