Chromalox PF455-3 User's Manual
Contents
1. Chromalox Installation Operation and RENEWAL PARTS IDENTIFICATION SERVICE REFERENCE owision 4 senon DH REFERENCE Supersedes PF455 2 PF455 3 161 562766 001 DATE FEBRUARY 2001 Chromalox Electric Airduct Heaters with Fintube Heating Elements Conduit Integral Controls Insert Type Figure 1 I DHRI Remote Controls Insert Type Figure 2 Entrance Plate Integral Controls Flanged Type Figure 3 DHRF Remote Controls Flanged Type Figure 4 GENERAL These heaters are designed to be installed in either a horizontal or vertical duct in one of the six positions shown in figure 16 The heater is constructed with individual 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 on page 7 before installing to insure the heater you received conforms to your specification 2010 Chromalox Inc Please read these directions carefully to insure all limitations are properly observed and all wiring and controls are properly installed and connected IMPORTANT Observe at least one complete heating cycle operation before leaving the installation GENERAL Limitations Ductwork must be in accordance with one of the fol lowing Standards of the National Fire Protection Association for the installation of Air Condi2. Element Static equalizers not shown maintain uniform air flow across the heater face when individual fintubes are omitted Contactor Air Flow Switch Automatic and Manual Reset Fusing not shown Contact your local Chromalox Sales Office with Complete heater catalog number or part number 6 CATALOG NUMBER DESIGNATION SYSTEM QOQO0Q00 OO0O 00H X 000W X 00 00D DOOVOADP 000 0kW 000 0kW 16kW Ft MAX Phase 1P Single Phase 3P Three Phase 0 Number of circuits OOOV Heater voltage up thru 600V 00 00 Depth of heater frame in inches 06 50 min 36 00 max OOOW Width of duct in inches 08 thru 120 OOH Height of duct in inches 06 thru 40 Terminal box construction and terminal box and frame material GPA General purpose terminal box and all aluminized steel construction GPP General purpose terminal box and all painted steel construction GPZ General purpose terminal box and all plated steel construction GPS General purpose terminal box and all stainless steel construction DPA Drip proof terminal box and aluminized steel construction DPP Drip proof terminal box and painted steel construction DPZ Drip proof terminal box and plated steel construction DPS Drip proof terminal box and stainless steel construction General style DHRI Duct heater remote controls insert type DHRF Duct heater remote controls flanged type DHII Duct heater integral controls insert type
3. Please refer to the Chromalox limited warranty applicable to this product at http www chromalox com customer service policies termsofsale aspx Chromalox PRECISION HEAT AND CONTROL 2150 N RULON WHITE BLVD OGDEN UT 84404 Phone 1 800 368 2493 www chromalox com
4. cut edges of duct as shown in Figure 19 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 hang er 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 sealant Mounting Procedure DHRI Insert heaters with compact terminal box 1 Measure dimension H of duct heater Figure 2 and mark the duct with an outline for a rectangular hole with dimensions of D 1 h x H The D 1 h dimension is to be parallel to the direction of air flow 2 Increase D 1 slot to D by forming a 7 4 double lip on each side of the duct See Figure 19 3 Slide heater into duct 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 Self Adhesive Gasket Supplied with Heater and Installed by Customer Control _ Box Sheet Metal Screws Sheet Metal Screws Mounting Holes Self Adhesive Gasket Supplied with Heater and Installed by Customer Control Box Sheet Metal Screws Mounting Holes Self
5. dampers or filters Maintain at least 4 dis tance between duct heater and damper filter frames or other similar obstructions Refer to Figure 13 Air Flow Damper e ne gt LA Top of Duct Figure 13 Clearance Zero clearance between duct heater and combustible materials such as wood is permissible However adequate clear ance must be provided around terminal box for proper ventilation and future service accessibility AIR FLOW 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 com pare 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 nameplate remembering inlet air temperature Velocities are best checked with an anemometer tak ing numerous readings along the horizontal and vertical centerline of the duct heater at th
6. Adhesive Gasket Supplied with Heater and Installed by Customer Figure 19 Self Adhesive Gasket Supplied with Heater and Installed by Customer Figure 20 WIRING 1 Connect heater only to the voltage frequency and phase spec AWARNING ified on the nameplate AWARNING 2 All wiring should be done according to local and National Wazard of electrical shock Any installation involv Electric Codes ing electric heaters must be grounded to earth to 3 Make supply connections to marked heater terminals using eliminate shock hazard wire suitable for 75 C Type RH RW or equivalent 4 Conduit attachment to heater Control Ratings E Manual Limit Control Automatic Limit Control Run conduit s to conduit entrance plate See Figure 1 Mark plate where conduit s will enter plate R Non Inductive Pilot Non Inductive mm ices e Reinstall plate and install conduit s to plate 9200 Watts Fan Interlock The fan circuit must be interlocked with the 6000 Watts control circuit of the heater Refer to the wiring diagram in the 5095 Walls heater terminal box AWARNING Hazard of severe shock Disconnect all power to heater before servicing BOOP WIRING DIAGRAM The appropriate wiring diagram will be supplied with each heater RENEWAL PARTS IDENTIFICATION Typical DHIF Duct Heater Conduit Entrance Plate Main Disconnect Transformer Fusing Air Flow Switc Transformer Fintube Heating
7. DHIF Duct heater integral controls flanged type OMP 00 00 O 00000000 Disconnecting Means ND Nonfused disconnect switch 200A max FD Fused disconnect switch 48A max TB Terminal block 200A max disconnect switch by others Control circuit voltage 000 120 208 240 or 277V Control circuit power supply T Control circuit by integral transformer 120V Sec Only R Remote control circuit by customer 120 208 240 or 277V Fan interlock method AS Air flow switch Fl Fan interlock relay FD Fan interlock relay with fan delay Heating element termination M Threaded terminals with mica insulation R Threaded terminals with ceramic insulation 480V max H Hermetic seals 480V max Method of attaching heating element to heater frame WA Painted steel fin and sheath GW Mounting washer staked to element sheath with gasket BF Brass fitting with gasket SS Stainless steel fin and sheath Sheath fin and finish of heating element PS Painted steel fin and sheath MO Monel fin and sheath SS Stainless steel fin and sheath Mounting position of heater 1MP See Figure 16 on page 4 mounting position 1 2MP See Figure 16 on page 4 mounting position 2 3MP See Figure 16 on page 4 mounting position 3 4MP See Figure 16 on page 4 mounting position 4 5MP See Figure 16 on page 4 mounting position 5 6MP See Figure 16 on page 4 mounting position 6 ae Limited Warranty
8. e location prior to installation or slightly up stream from the heater after installation Refer to Figure 14 Large ducts will require additional readings taken at locations in addition to the centerline Duct Heater Velocity Profile Figure 14 Incoming Air Temperature Incoming air temperature entering the duct heater must not exceed 100 F Example 500 FT MIN Minimum Air Velocity on Heater Nameplate 600 500 700 Velocity 600 Profile 900 FT MIN 700 600 500 500 FT MIN MINIMUM 200x 400x 800 Velocity 900 Profile 600 FT MIN 700 200x 300x 400x 9 4500 500 FT MIN AVERAGE WRONG X below 500 FT MIN MOUNTING Multiple Duct Heaters Up to six duct heaters may be combined into a heating bank as shown in Figure 15 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 hor izontal or vertical duct Heaters must be mounted in the position designated by arrows on the heater frame Refer to Figure 16 The heater terminal box on vertical duct installations can be located on any side of the duct but for horizontal duct installation the terminal box must be on the side of the duct AWARNING This heater is not intended for use in hazardous atmospheres where flammable vapors gases liq uids or other comb
9. n cut edges of duct as shown in Figure 17 Omit flange in side when terminal 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 hang er straps or duct 5 Where necessary joint between duct and heater flange may be sealed with silicone gaskets or silicone sealant Mounting Procedure DHII Insert heaters with control box 1 Measure dimension H of duct heater Figure 1 and mark the duct with an outline for a rectangular hole with dimensions of D 1 h The D 1 dimension is to be parallel to the direction of air flow 2 Increase D 1 4 slot to D by forming a 3 4 double lip on both sides of the duct opening See Figure 18 3 Slide heater into duct 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 Procedure DHRF Flanged heaters with compact terminal box 1 At heater location cut out a section of duct or on new con struction lay out duct work to accommodate dimensions of heater 2 Form mounting flanges on
10. ncreased by a sheet metal tran sition The slope of the transformation piece on the upstream side of the equipment is limited to 30 as indicated in Figure 9 On the leaving side the slope should not be more than 45 Duct Heater 7 4 Ft Min Figure 9 External ra Insulation a a ee Leave Control Box Uninsulated Figure 10 GENERAL 7 Installation in duct larger than heater For installation where the duct dimensions exceed the insert type heater dimensions the area beyond the heater dimensions must be filled with wire mesh expanded or perforated sheet metal of 50 open area as shown in Figure 11 This will maintain a uniform air velocity across the face of the duct Inner Baffle Insert Type Perforated Metal Duct Heater 50 Open Area rrine amarrean rerama amarrean reran a amarrean Remove Bracket and Use Sheetmetal Screws Thru Same Holes into Duct Oversized Duct Figure 11 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 temperature Refer to Figure 12 9 Do not install duct heater outdoors Duct heaters cannot be installed with rooftop equipment where they are exposed to the weather Flexible Duct Must be suitable for 195 F Duct Heater Figure 12 10 Installation with
11. tioning and Ventilating Systems of other than Resident Type Pamphlet 90A or Residential Type Warm Air Heating and Air Conditioning Systems Pamphlet 90B Location Chromalox Duct Heaters may be located anywhere in the duct system NOTE The minimum distances shown are limitations Wherever possible locate as far away from these limits as practical In any case this distance with any required airflow correction must be sufficient to accomplish 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 5 Duct Heater Heat Pump Central Air Conditioner Filters or Humidifier Figure 5 2 Installation near air handler discharge Refer to Figure 6 Duct Heater Air Handler Figure 6 3 Installation in branch duct take off Refer to Figure 7 4 Ft Min Straight Section Duct Heater Figure 7 4 Installation near turns Refer to Figure 8 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 Duct Heater Here or Here Figure 8 Installation with duct transitions in some air distribution sys tems the duct heater may be considerably larger than the duct work and the duct area must be i
12. ustible atmospheres are pre sent as defined in the National Electric Code Failure to comply can result in explosion or fire Figure 15 Figure 16 IT Pra i S a ARTINE ithe Rarer ere SALET Mey w g eun pu KINE ug Z AR P cate entry for style DHRI amp DHRF heaters Air box entry for style DHRI amp DHRF flow as shown Install with this arrow up heaters Air flow as shown Install with this arrow up Mounting position 2 entry for style DHRI amp DHRF heaters Air HORIZONTAL DUCT side terminal box 4 HORIZONTAL DUCT side terminal flow as shown Install with this arrow up VERTICAL DUCT side terminal air Mounting Position 1 Mounting Position 3 Cinta _ aco eA a mc ny GSAT ti a ay Bra HORIZONTAL DUCT Side terminal HORIZONTAL DUCT Side terminal VERTICAL DUCT Side terminal box box entry for style DHII amp DHIF heaters Air flow as shown Install with this arrow up Mounting Position 4 box entry for style DHII amp DHIF heaters Air flow as shown Install with this arrow up Mounting Position 5 entry for style DHII amp DHIF heaters Air flow as shown Install with this arrow up Mounting Position 6 MOUNTING Mounting Procedure DHIF Flanged heaters with control box 1 At heater location cut out a section of duct or a new con struction lay out duct work to accommodate dimensions of heater 2 Form mounting flanges o
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