open coil duct heaters
Transcription
open coil duct heaters
Page 1 - GENERAL INFORMATION Pneumatic Electric Switches SCR (Solid State Devices) Three Types Secondary (back-up) Systems A - INTRODUCTION 1 - GENERAL DESCRIPTION A Duct Heater is a self contained heater designed to be installed in the field in an air stream of a duct system, external to the air moving unit. It is designed to be installed in a duct where an adequate flow of air from a separate, interlocked fan or blower system is insured. Such a heater may be located in a main supply duct of a warm air heating system, in one of the branch ducts, or used as a room heater, at the end of a branch duct. In this catalogue, pricing and detailed data are given regarding application and usage of the various required and optional equipment. 4 - FLEXIBLE CUSTOM DESIGN Inducto Duct Heaters are listed by the Underwriter's Laboratories Label Service Department (UL Reference Number E33694) ranging from five hundred watts to one million watts, to fit ducts from a minimum of six inch height x ten inch width to a maximum of eighty inches height x twenty feet in width. This range makes the duct heater the most versatile type of heating system. Inducto Duct Heaters are approved for zero clearance to combustible surfaces, and meet all UL, and 1975 National Electrical Code requirements. Heaters are available for 120, 208, 240, 277, 480, 550, and 600 volt electrical rating, single or three phase with control voltages of 24, 120. 208, 240 or 277 volts. Inducto Duct Heaters are packaged units, completely wired for simple connection to the power supply system. With the cover removed. line terminals are completely exposed in a large terminal box. Conduit knockouts and detailed wiring diagrams are included in each unit. Electric Duct heaters are an ideal answer for the heating system designer, because of electricity's inherent cleanliness as a fuel, their adaptability for use with other comfort conditioning components, such as humidifiers, de-humidifiers, electronic filters and heat pumps, and their flexibility for use with a variety of control systems to maintain the precise temperature desired. Markel has one series of Inducto Duct Heaters to accommodate all applications. Series HF custom designed flange and insert heaters. This series has built-in primary and alternate types of secondary over-temperature safety protection to meet the 1975 National Electrical Code, and UL requirements. 2-ADVANTAGES Open Coil Inducto Duct Heaters: Patent Module Design Clean Heat Double Safety Protection Low Cost Factor UL Listed Instant Heat Solid Cover for Dust Elimination Custom Design Insulated Control Panel (Standard) Low Static Pressure Drop B - TYPICAL APPLICATIONS 1 - Prime Heating: Inducto Heaters are supplying prime heat in thousands of installations throughout the United States and foreign countries. They are used to heat all types of industrial and commercial buildings, schools, hospitals, churches, residences, and for all types of remodeling. 2 - Air Handling Equipment: Manufacturers of cooling and air handling equipment have found electric heating coils to be a valuable addition to their air handling units. Inducto Heating Coils are built to replace and fit into space provided for other types of heating coils. Usually no re-design or alteration of present equipment is necessary. 3 - Heat Pumps: Inducto Heaters are used as supplementary heat with heat pumps. When outside temperatures drop below the efficiency range of the heat pump, the heating coils provide the necessary additional heat. 3 - OPTIONAL EQUIPMENT HF series are available with the following optional equipment: Built-in or Remote: Magnetic Controlling Contactors Step-down Transformers for control voltage supply Fuses for over-current protection Circuit Breakers for over-current protection Time Delays Mercury Contactors Indicator Lights Disconnect Switch Pilot Switches 4 • Zoned Application: Where there is considerable heat gain or loss variation in different locations throughout a building, small blast coil heaters are actuated to compensate and prevent over-cooling. SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE 2 Page 2 - CONSTRUCTION A - FRAME FIGURE 2 NOTE: 'OH' can apply to overhang on either side of heater FIGURE 1 The terminal compartment extends beyond the element enclosure at least 1/2 inch on all sides so that it will cover the rough opening in the duct. When additional space is required for built-in components the terminal box is extended on the air inlet side as standard, or leaving air side either up or down if specified. The "A" dimension can be extended as an overhang when specified. 1 - Insert Heaters are the most generally used type because of the ease of installation in the duct system. The heating element enclosure is inserted in the air stream through a hole cut in the side of the duct, and is secured by means of screws applied from within the terminal box. ****** ******** FIGURE 4 The flanged element enclosure and the terminal compartment are flush on the air outlet side. When "M" dimension exceeds "B" dimension, the overhang will be on the air inlet side, as standard, or leaving air side either up or down if specified. The "A" dimension can be extended as an overhang to provide space for components when specified. 2 - Flanged Heaters are custom designed to be installed as an integral part of the duct system. The inside of the flange d frame is the same dimensions as the air duct, allowing for mating with, and securing to the duct flanges. A one inch flange is supplied as standard, unless otherwise specified. SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE 3 CONSTRUCTION . Page 3 3 - Internally Insulated Duct Applications: 4 - Bottom Terminal Box Heaters: Inducto Internally Insulated Ducts can affect the Heaters are specially designed to accommodate operation of insert and flanged duct heaters and installations where side mounting is not possible. therefore, must be specified so that the Since the resistance element wire must be strung following design factors can be employed which horizontally the safety controls are located in will allow the air stream to pass over the limit the side terminal compartment. Other controls controls and all elements. except mercury contactors and fusing are located in bottom control box. Heaters limited to 60 KW max. Remote fusing required for all heaters over 48 Amps. Pricing under Optional Pricing Section. INSERT TYPE The element enclosure is reduced in size enough to allow the entire face of the control box to be recessed into the duct to the depth of the insulation. An angle is installed on all four sides of the terminal compartment to seal the opening and provide a mounting means. FLANGE TYPE FIGURE 7 - Bottom Terminal Box 5 - Dust Proof Terminal Box Cover: Inducto Heaters are available with a dust tight control box cover where dirt problems could affect the life expectancy of the controls. Pricing found under Optional Pricing. 6 - Multiple Heaters in a Single Duct: Inducto Duct Heaters are designed as single units in all applications except where height dimension exceeds 80". Heaters above 80" will be furnished in two or more flanged sections for stacking one on top of the other, for simplifying shipping and field installation. A special foot design is furnished with these flange units for easy mounting when stacked. Automatic A deeper flange is required so that the inside of the flanged housing is flush with the surface of the insulation and the face of the terminal compartment is recessed to the depth of the insulation. FIGURE 8 - Multiple Heaters in a single duct. 4 Page 4 - CONSTRUCTION resetting temperature limits are furnished in each heater section, with provisions for wiring them in series in the field. Built-in accessories, such as contactors, and fusing, are also available. Separate power lines are required for each section. When preferred, heaters with a long "W" dimension can be divided into two separate units and one installed from each side of the duct. B - DIMENSIONAL DATA The HF series terminal compartment depth "E" is normally 4 1/2", however it may be increased when necessary. The "H" and "W" dimensions are the actual duct height and width. "C" and "M" dimensions depend on several factors and must be calculated by the factory engineering department, however where conditions limit the size this must be specified. The HF series compartment has a solid cover that is hinged on the top or otherwise, also a latch is provided. A support bridge is installed on the bottom of the element enclosure on all heaters when "W" dimension exceeds two (2) feet. (See figure 1, 2 and 3). FIGURE 9-Typical Insert Heater FIGURE 11 - Bottom Terminal Box C - CORROSION PROTECTION Inducto Duct Heaters are constructed of the highest grade galvanized steel (standard), aluminized (optional). All other metal components are either zinc plated or constructed of stainless steel. This type of protection gives longer life and prevents damage by moisture from cooling systems. D-INSULATION Each heater is manufactured with a 1/2" fiberglass board insulation between the control box and the duct area. This type of insulation gives maximum protection against moisture condensation as well as thermal insulation. In installations where noise is a factor, such as high rise apartments, this type of insulation absorbs part of the air movement sound. E- HEATING ELEMENT 1 - Open Coil Type: The open coil element offers many advantages over the sheath type. One of the greatest assets is its longer life. The open coil releases its heat directly into the air stream, transferring its energy faster, and therefore operating at a cooler temperature. The sheath type element must release its energy through an insulation and the metal outside sheath. Due to this slower transfer, life expectancy is reduced and service requirements increased. In some cases, the insulation may contain voids, in which case, the conduction is reduced creating possible burn-outs. The open coil gives greater adaptability in design and lower pressure drop across the unit. This feature can help the systems designer maintain a lower static pressure, and thereby reduce the air handling power requirements, design and system costs. FIGURE 10-Typical Flanged Heater SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE 5 CONSTRUCTION - Page 5 G - ELEMENT TERMINATION The coil is mechanically connected to the high temperature No. 10 stainless steel terminal screw by means of a loop of element wire being sandwiched between two stainless steel washers. Since a large area of element wire is used in making the connection, burn-outs due to nicked wire at the connection are minimized. The terminal is insulated by a two piece mating male and female ceramic bushing. The low mass coil releases heat immediately after being energized and cools quickly after being de-energized. The low thermal inertia results in more precise temperature control. 2 - Element Construction: The Inducto Duct Heater elements are constructed of high grade resistance wire. Each element is coiled to the customer's wattage specification in our plant, assuring high quality elements with a closely controlled resistance. Each element is checked when produced, and again upon installation in the heater. Inducto heating element coils are designed for low watt density loading of the surface area of the wire (40 to 60 watts per square inch). A heavier than normal guage wire is used, giving a longer coil to maintain required resistance for a given wattage. This results in lower coil operating temperature which eliminates glow under standard operating conditions because of the greatly increased surface area and also gives a sturdier element for longer life. F - MODULAR FRAME AND CHANNEL RACK The HF series heaters are furnished with a new galvanized, (aluminized optional) modular frame. This design has made it possible for easier servicing in the field should this be necessary. The new HF channel rack has been designed to give added rigidity and also improved heat dissipation due to staggering of the rows of heating elements. (See Below) FIGURE 13 - Element Termination H - INSULATING BUSHINGS The high temperature special ceramic bushings, which insulate the coils from supporting metal, float freely in specially designed element racks. The floating ceramics will not crack or bind due to heating and cooling of the element. I - STEEL WELDED SAFETY SCREEN When the requirements for additional safety from possible contact to the heating elements of a duct heater, either from entering air or leaving air side, a screening material is available factory installed and UL approved as an option. Refer to Optional Pricing Section. J - ELECTRIC DUCT HEATERS FOR MULTI-ZONE APPLICATIONS For many years Inducto has been developing and manufacturing heaters for multi-zone applications. This type of application has been used in office buildings, auditoriums, schools, and many other constructions where different conditioning is required at one time. The air flows in this type of unit are controlled FIGURE 12 - Typical Channel Rack 6 Page 6 -CONSTRUCTION 6 - CAPILLARY TYPE AUTOMATIC AND MANUAL RESETS Each heater contains double protection in the use of the capillary type automatic and manual reset limits. Both types of safety devices have capillaries extending the full length of the. heater and can sense thermal overload at any point along its length. Upon sensing the over temperature the unit is shut down. by hot deck and cold deck dampers, each having a possible air flow from zero to 100 percent. Therefore a zone calling for 100 percent heat would have its cold damper closed and the hot damper fully open. The opposite is true when 100 percent cold air is required. Two adjacent zones, serving separate sections of a building, could have the dampers in an opposite position mode. This results in a variable air flow pattern across the heating coil. Therefore, special considerations must be made when designing an electric heater for the' multi-zone application. These special design characteristics are as follows: 7 - DISTANCE TO DAMPERS The distance between zone dampers and the coil should be at least 18 inches. If this distance is not maintained, overheating of the coil may result. 8 - CONTROLLING MEANS The stages of the heating coil should be controlled by a temperature sensing device placed in the leaving air stream. The steps of the heater should be decreased as the rise requirements are decreased. This decreases the density of the coil as less temperature rise is required and air flow decreased. All of the Inducto multi-zone heaters are constructed with open coil elements because of their better operating characteristics over the finned tubular elements. These advantages are discussed on page 10 section II Construction paragraph E. The combination of Inducto multi-zone heaters and multi-zone units should be made in accordance with NEC and local governing codes. The Inducto multi-zone heaters will be built in accordance with Underwriters Laboratories Standards; however, they will not bear the UL label due to the vast testing required of the many different combinations. 1 - LOW DENSITY ELEMENTS Low watt density coils are required to reduce surface temperatures to a minimum during low air flow operation. The Inducto elements are derated to one-half or less than the normal watt density. This prolongs element life and decreases radiation. 2 - MINIMUM NUMBER OF STEPS Due to the various amounts of KW required and space available in the hot decks, each application must be considered separately as to the number of steps. In any case, less than three steps are not recommended. The greater the number of steps, the greater the uniformity of temperature control. 3- FREE AREA Each multi-zone unit must have the electric heater specifically designed for its free area of air flow. All restrictions as to air flow must be considered in order to assure that all regulating and safety controls are in the air stream as well as the entire face of the heater. This assures that safety limits are able to function properly giving maximum protection and eliminating undue cycling which would decrease element life. 4 - ELIMINATION OF STRATIFICATION In order to prevent stratification and use the maximum amount of air flowing across the coil, each step should have a spread across the full face of the heater. This is necessary especially when only one or two dampers are open. 5-BAFFLE PLATES Perforated baffle plates should be provided on the air inlet side of the heater to assure an even air distribution across the face of the coil. This is an important function in low air flow usage of the coil. SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE 7 INSTALLATION DESIGN AND PROCEDURES - Page 7 A-GENERAL DESIGN INFORMATION TEMPERATURE RISE The air temperature rise through the heater is 9 factor of great importance. The chart should be consulted for the temperature rise expected to result from the air flow and watt density used. 1 - The Temperature Rise Chart (Fig. 1) aids in calculating requirements or results from the known factors of FPM, CFM, Temperature Rise, Total KW, or KW per square foot. If two related factors are known, the others can be determined. EXAMPLE B VELOCITY (FPM)-WATT DENSITY (KW PER SQ. FT.) To find the watt density (KW per sq. ft.) at a given temperature rise and F.P.M. of air, use bottom and left scales. EXAMPLE: To find the heat input in a duct handling 700 F.P.M. of air, with a temperature rise of 60ºF. 1. Draw a line vertically up from the 700 F.P.M. on the bottom scale to the 60°F. temperature rise line. 2. From the point of intersection draw a horizontal line to the left side scale giving 13.5 KW per sq. ft. of duct area. 2 - Minimum Velocity Requirements: Electric duct heaters are different from steam or hot water coils, in that the B.T.U. output remains constant as long as the heater is energized. To eliminate over-heating and burn out due to low air velocity, an automatic re-set temperature limiting control is built into each heater. The minimum velocity required to prevent nuisance tripping of the temperature limiting control is determined from the air velocity chart (Fig. 2 on the basis of entering air temperature, and watts per square foot of cross sectional duct area. CFM CAUTION - DO NOT OPERATE WITHOUT PROPER AIR FLOW For efficient and trouble free operation it is important that air flow be adequate over the complete heating area and particularly at element terminals. No electric duct heater should ever be operated with insufficient air flow because overheating and subsequent malfunction may result. The minimum air velocity required at any point should be determined from the graph following. MINIMUM AIR VELOCITY REQUIRED FOR PROPER OPERATION FIGURE 1 NOTES: (A) For values above or below those on the scale, multiply or divide the known factors by a convenient number. Make the necessary calculations on the chart, then multiply or divide the answer by the original number for the actual value. (B) If any two factors are known the third may be calculated in a similar manner. EXAMPLE A Air (CFM)-(KW) Total Heat Required To find the total heat required at a given temperature rise and CFM, use the top and right scales. EXAMPLE: The heat required to achieve a 40°F temperature rise in a duct handling 12,000 C.F.M. 1. Draw a line vertically down from the 12,000 C.F.M. on the top scale to the 40°F. temperature rise line. 2. From the point of intersection draw a horizontal line to the right side scale. Giving total heat required 150 KW. Formula: H X W divided by 144 = sq. ft. /area KW divided by area = KW/sq. ft. duct area (density) H = Element Frame Height W = Element Frame Width 8 Page 8 - INSTALLATION DESIGN AND PROCEDURES 3 - Available Watt Density: "HF" series Inducto Duct Heaters are built to the wattage and dimensions as specified by the customer. The "HF" series heaters are available to 1000 KW in all wattages up to 20 KW per square foot of cross sectional duct area and are suitable for installation with zero clearance to combustible surfaces and up to 100 degrees Fahrenheit inlet temperature. These heaters are available through 20 feet in width. C - INSTALLATION RESTRICTIONS The following are stated requirements of UL regarding installation of duct heaters. B - INSTALLATION RECOMMENDATIONS 1 - Should be installed at least 4 feet from a heat pump or central air conditioning unit. FIGURE 3 FIGURE 7 2 - No clearance is required between the duct and combustible surfaces around the duct for Inducto "HF" series duct heaters. FIGURE 4 1 -The heater must be installed to assure equal air flow through the entire face area of the heater. Refer to N EC par. 424-59. FIGURE 8 3 - A duct heater must not be installed so that the heating element coils are strung vertically through the supporting racks. FIGURE 5 2 - A canvas vibration insulation connector should not be located less than 18 inches from a duct heater. If it is located closer, an asbestos connector should be used. DUCT HEATER PRESSURE DROP SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE 9 INSTALLATION DESIGN AND PROCEDURES • Page 9 Series HF INSTALLATION. OPERATING AND MAINTENANCE INSTRUCTIONS FOR INDUCTO ELECTRIC DUCT HEATERS APPLICATION REQUIREMENTS 1. The duct system must provide uniform air flow over the entire face area of the heating elements. 2. For satisfactory and safe operation the minimum air velocity must be maintained as determined from table. 3. The air duct should be installed in accordance with the standards of the National Fire Protection Association for the installation of air-conditioning and ventilating systems of other than residence-type (Pamphlet No. 90A) and residence-type warm air heating and air-conditioning systems (Pamphlet No. 90B). 4. The heater should be installed at least 48 in. from the duct flanges of a heat pump or central air conditioner. 3. Insert Type (Fig. 1) - Cut a hole in the side of the duct 1/8" larger than the element housing (H-1 x C) and insert the heater. Attach the back of the terminal box to the duct. 4. Flanged Type (Fig. 2) - Provide duct flanges to match heater flanges. Attach the heater to the duct flanges with screws. 5. Maximum inlet air temperature is 100° F. 6. Series HF heaters may be installed in duct systems having zero clearance to combustible surfaces. INSTALLATION PROCEDURES 1. Make sure air flow arrow on heater corresponds to air flow through the duct and heater is properly positioned if marked with "top." 2. The heater terminal compartment should not be enclosed by insulation, etc. HF 9-2-7 5 10 Page 10 - INSTALLATION DESIGN AND PROCEDURES ELECTRICAL WIRING INSTRUCTIONS SIZING OF SUPPLY CONDUCTORS WARNING: DISCONNECT ALL POWER SOURCES BEFORE DOING ANY WORK ON THE HEATER INSTALLATION. 1. Use the wiring diagram supplied with the heater as a guide in correlating field wiring with the heater internal wiring. If there is more than one heating step, wire the unit so the steps are energized in the same sequence as numbered in the heater. 2. All field wiring to the heater must meet the requirements of the N.E.C. and applicable local codes. 3. Wiring to the heater must be rated for 75° C. minimum. 4. Supply conductors must be sized to carry at least 125% of the ampere load of the circuit it supplies. 5. For low voltage control circuits, use NEC Class 1 wiring as described in Article 725 of the National Electrical Code. 6. The fan must be interlocked with the heater so that the heater is not energized unless the fan is on. A typical method of accomplishing this is shown on the wiring diagram, if it is not built in. 7. If contactors are field supplied, they must have adequate ratings for the load carried and be UL listed for 100,000 cycles of operation. Do not exceed the control circuit volt-ampere rating marked at the control terminal block. 8. If heater does not have a built-in disconnect switch or main circuit breaker, install a remote disconnect (furnished by others) in accordance with the National Electrical Code, Article 424-65. 9. Do not bundle, tie or wrap power wiring in groups as this may cause over-heating and eventual breakdown of insulation. 10. For low voltage control circuits using two supply transformers with a heating-cooling thermostat, one for heating and one for cooling, a thermostat with isolating contacts must be used to prevent interconnection of the two different circuits. Caution: For successful service using aluminum wiring, special treatment of all connections is an absolute necessity in order to prevent high resistance and oxidation problems. For recommended practice check with your local electrical utility. OVERCURRENT PROTECTION UL requires compliance with paragraph 424-22 (b) of the National Electrical Code as follows: "Electric space heating equipment employing resistance type heating elements rated more than 48 amperes shall have the heating elements subdivided. Each subdivided load shall not exceed 48 amperes and shall be protected at not more than 60 amperes." This means that sub-circuit overcurrent protection must be provided if the total heater load exceeds 48 amperes. If overcurrent protection is not built-in, all heaters exceeding 48 amperes total line current are divided into a sufficient number of sub-circuits, each provided with line terminals for connection to remote overcurrent protection. The required minimum size of supply conductors is marked at the field wiring terminals within the heater control box, however for reference the following table is included. The wire gauges are calculated for 125% of the heater line current as required by the National Electrical Code, Article 424-3 (b) based on conductor insulation rated for 75° C (167° F) (1) For 7-24 conductors in a raceway or cable reduce allowable heater line currents to 87 ½ % of those shown above. (2) Based on 30° C (86 °F) ambient temperature. For higher ambient temperature, see N.E.C. table 310-16 and 310-18 Note 13. (3) Based on 80% of ratings in table 310-16 N.E.C. for 75 °C insulation. (4) Based on 80% of ratings in table 310-18 N.E.C. for 75 °C insulation. CALCULATION OF LINE CURRENTS (AMPS) MAXIMUM KW PER CIRCUIT FOR OVER-CURRENT To determine the line current, use the following formulae: Two or more circuits may be paralleled to make one heating stage. SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE 11 ELECTRICAL DESIGN - Page 11 3 - Ohm's Law A - GENERAL The requirements and practices described below are based on the National Electrical Code and the Space Heating Standard of the Underwriters Laboratories, Inc. (UL). Although UL requirements are uniform throughout the country, local electrical codes may deviate from the National Electrical Code, therefore local inspection authorities should be consulted regarding local requirements. After final assembly and before shipping each Inducto duct heater must pass a 2000 volt minimum dielectric test. 1 - Effect of low voltage on wattage and B.T.U.: The heating elements may be used on voltages lower than the design voltage of the heater, however, the wattage and B.T.U. output will he reduced to the percentage listed in table 1. FIGURE 1 DE-RATED WATTAGE FOR LOW VOLTAGE Heater Line % of Heater Voltage Voltage Wattage & B.T.U. 480 277 240 208 120 460 440 265 254 92% 84%, 92% 84% 230 220 208 200 200 190 92% 84% 75% 69% 92% 83% 115 110 92% 84% Ohm's Law Equation Wheel This "wheel" shows the equation for calculating any one of the basic factors of electricity - Watts (W). Amperes (I), Volts (E) or Ohms (R) - when any two of these factors are known. The elements to be calculated are shown on the rim of the wheel. Each quadrant shows three equations for solving the unknown; select the equation appropriate for the known values. Example: a 2400 Watt Single Phase heater is connected to a 240 Volt circuit. How many Amps does it draw? Solution: Since we are finding Amps, the formula will be found in the I (Amperes) section of the wheel. TABLE 1 W/E = 2400 W ÷ 240 V = 10 Amps 2 - Standard Voltages: Inducto duct heaters are built in five standard voltage ratings to cover the voltage ranges listed in Table 2. If a specific voltage is required, the order must be marked "specific voltage - V." For heater output on reduced voltage see Table 1. What is the Resistance? 2 E /W = R 240 V x 240 V ÷ 2400 W = 24 Ohms STANDARD VOLTAGES If you order: 110 V 208V 220V 254V 440V Ratings You will get: 115V., etc. 120 V. 208 V. 230V, 236V, etc. 240 V. 265V, 277V. 277 V. 460V, etc. 480 V. from 500 V. up to 600V. will be furnished as ordered. TABLE 2 12 Page 12- ELECTRICAL DESIGN 4 - ELECTRICAL CODES AND REGULATIONS The design and installation of electric duct heaters must conform to all codes and regulations apply ing at the job site in addition to meeting the specifications. These include standards and requirements published by Underwriters' Laboratories. Inc. (UL), National Electrical Code (NEC). and other state and local agencies. Ductwork must be installed in accordance with one of the following standards of the National Fire Protection Association: Installation of Air Conditioning and Ventilating Systems (1972 Pamphlet 90A), or Residence Type Warm Air Heating and Air Conditioning Systems (1968Pamphlet 90B). NATIONAL ELECTRICAL CODE INDUCTO QUALIFICATIONS Inducto duct heaters are designed to comply with Paragraph 424-58. Approved. Heaters installed the provisions of the National Electrical Code, UL, in an air duct shall be identified as suitable for the and other regulations. installation. Compliance with this requirement is the Paragraph 424-59. Air Flow. Means shall be responsibility of the system designer and provided to assure uniform and adequate air installer. Minimum air velocities for Inducto flow over the face of the heater. heaters are shown in the installation instructions. Heaters installed within 4 feet of a fan outlet, elbows, baffle plates, or other obstruction in duct work may require turning vanes, pressure plates, or other devices on the inlet side of the duct heater to assure an even distribution of air over the face of the heater. Inducto heaters are approved for use with heat Paragraph 424-60. Elevated Inlet Temperature. pumps. Critical performance data for each Duct heaters intended for use with elevated inlet heater is clearly indicated on the heater as well air temperature (such as heat pumps) shall be as in the installation instructions. Lower watt approved for the purpose and so marked. density heaters may be specified for special applications. Paragraph 424-61. Installation of Duct Heaters with Heat Pumps and Air Conditioners. Heat pumps and air conditioners having duct heaters closer than 4 feet to the heat pump or air conditioner shall have both the duct heater and heat pump or air conditioner approved for such installation and so marked. Paragraph 424-62. Condensation. Duct heaters used with air conditioners or other air-cooling equipment that may result in condensation of moisture shall be approved for use with air conditioners. This pertains to the design and installation of heat pumps rather than to duct heaters. Inducto does recommend that a duct heater should be installed at least 4 feet downstream from heat pumps and air conditioners and at least 2 feet downstream from air handlers. All Inducto duct heaters are assembled with a 1/2" fiberglass board insulation permanently attached to the duct side of the control compartment as standard. This construction provides maximum protection against condensation. These heaters are UL listed and marked - "For use with heat pumps or central air conditioners." Inducto heaters are available on order with a built-in airflow switch, or fan interlock relay. Paragraph 424-63. Fan Circuit Interlock. Means shall be provided to insure that the fan circuit is energized when the first heater circuit is energized. However, time or temperature controlled delay in energizing the fan motor shall be permitted. SPECIFICATIONS SUBJECT TO CHANGE WITHOUR NOTICE 13 ELECTRICAL DESIGN - Page 13 All Inducto standard and custom duct heaters include a primary auto-reset high limit switch and a secondary disc type replaceable - all readily accessible in the heater control compartment. Paragraph 424-64. Limit Controls. Each duct heater shall be provided with an approved, integral, automatic-reset temperature-limiting control or controllers to de-energize the circuit or circuits. In addition, an integral independent supplementary control or controllers shall be provided in each duct heater that will disconnect a sufficient number of conductors to interrupt current flow. This device shall be manually resettable or replaceable. Paragraph 424-65. Location of Disconnecting Means. Duct heater controller equipment shall be accessible with the disconnecting means installed at or within sight from the controller. Paragraph 424-20. Controllers and Disconnecting Means. (a) Thermostats and thermostatically controlled switching devices that indicate an off position and interrupt line current shall open all ungrounded conductors when the control device is in this off position. (b) Thermostats and thermostatically controlled switching devices that do not have an off position shall not be required to open all ungrounded conductors. (c) Remote-control thermostats shall not be required to meet the requirements of (a) and (b) above. These devices shall not be considered as the disconnecting means. (d) Switching devices consisting of combined thermostats and manually controlled switches that serve both as controllers and disconnecting means shall: (1) Open all ungrounded conductors when manually placed in the off position. (2) Be so designed that the circuit cannot be energized automatically after the device has been manually placed in the off position. Paragraph 424-22. Overcurrent Protection. (b) Resistance Elements. Electric space heating equipment employing resistance-type heating elements rated more than 48 amperes shall have the heating elements subdivided. Each subdivided load shall not exceed 48 amperes and shall be protected at not more than 60 amperes. (c) Overcurrent Protective Devices. The overcurrent protective devices specified in (b) above shall be: (1) factory-installed within or on the heater enclosure or provided as a separate assembly by the heater manufacturer; (2) accessible, but shall not be required to be readily accessible; and (3) suitable for branch-circuit protection. Inducto custom heaters may be ordered with a factory installed electrical disconnect switch sized to the total heater capacity (200 amp max. per switch). Inducto heaters are furnished with built-in contactors and other control devices for total disconnect of all ungrounded conductors or for circuit de-energizing. Circuit de-energizing will normally be furnished. To meet this requirement, Inducto heaters are available with built-in fusing and circuit breakers. All heaters exceeding 48 amperes total line current are divided into subcircuits (as allowed by stages) of less than 48 amperes and are protected at not more than 60 amperes. The main conductors supplying these overcurrent protective devices are considered branch circuit conductors and are subject to the 125% ampere rating rule. 14 Page 14- ELECTRICAL DESIGN 4 - Electrical Codes and Regulations (Cont.) Underwriters Laboratories Inc. Standards for Safety No. 1096 UL REQUIREMENTS TRANSFORMER PRIMARY OVERCURRENT PROTECTION 17.11 Overcurrent protection at not more than 20 amperes shall be provided by a suitable circuit breaker or fuses, as a part of the heater, (1) for each general-use duplex receptacle circuit, (2) for each transformer primary circuit, except as indicated in paragraph 17.14, and (3) for each lampholder circuit, except as indicated in paragraph 17.12, independent of a heating element, unless the heater would be properly connected in accordance with the National Electrical Code to a branch circuit rated at 20 amperes or less. See para graph 35.2. 17.14 The overcurrent protection may be omitted from the primary of a Class 2 transformer. 35.2 A heater intended for use of a 15 or 20 ampere circuit, as indicated in paragraph 7.12, shall be marked; Use Only On a Ampere Branch Circuit. INDUCTO QUALIFICATIONS Inducto Heaters are provided with a control transformer when specified or requested. When a control transformer is built-in to a heater or remote control panel the primary of the transformer will be protected per code and the standard requirement is: (a) Class II trans. are integrally protected and will be additionally protected only when specifically requested, (b) All other transformers will be connected within the heater to a circuit of 16 amp. maximum if available, otherwise separate primary fusing will be installed. Though not required the secondary of the transformer will be fused if specified. a The number 15 or 20 as appropriate. FACTORY INSTALLED CONTROLS 23.12 A contactor or similar device, such as a silicon controlled rectifier, required for use with a limit control shall be provided by the manufacturer of the heater, but need not be mounted on the heater. See paragraph 34.10. 34.10 If required overcurrent protective devices or contactors are provided as a separate assembly, see paragraphs 17.2 and 23.12, the heater shall be marked to indicate that it is to be used only with this separate assembly. 17.2 The overcurrent protective devices required by paragraph 17.1 shall be provided as an integral part of the heater or shall be provided by the heater manufacturer as a separate assembly, for independent mounting, for use with the heater. See paragraph 34.10. In some applications the required components cannot be built in the duct heater terminal box because of space limitations, inaccessibility, etc. In this case some, or all, of the components can be mounted and factory wired internally, as applicable, in a panel for remote mounting. All terminals are marked to clearly indicate the field connections between the panel and the heater. The panel is of the same construction as the heater terminal box and the same components will be used as previously described in this catalogue for use in the Inducto duct heater. Both the heater and the remote control panel must be UL listed, so labeled, and completely coordinated. SPECIFICATIONS SUBJECT TO CHANGE Wl TH OUT NOTICE 15 ELECTRICAL DESIGN . Page 15 CONTROL COMPARTMENT COVER 5.11 Except as indicated in paragraph 5.13, the door or cover of an enclosure shall be hinged (1) if it gives access to any fuse, circuit breaker, or manually resettable temperature control in other than a low-voltage circuit, and (2) if uninsulated live parts are exposed during the normal replacement of the fuse or resetting of the manually resettable device. Such a door or cover shall also be provided with an automatic latch, see paragraph 5.15, or the equivalent and, if live parts other than the screw shell of a plug fuseholder are exposed inside the enclosure, a captive screw or equivalent means, requiring the use of a tool to open, to reliably secure the door or cover in place. See paragraph 5.12. 5.15 A spring latch, a magnetic latch, a dimple, or any other mechanical arrangement that will hold the door closed, and would require some effort on the user's part to open it, is considered to be a suitable means for holding the door closed as required in paragraph 5.11. 5.12 The captive screw may be omitted from the door or cover over the compartment housing the uninsulated live parts if it is provided in the cover that must be opened to gain access to the door or cover. Arrangements employing two mating hinged doors are acceptable where the automatic latch and captive screw are provided only on one door (1) if that door is designed to be opened first and closed last, and (2) if the latch and screw will hold the other door closed. ZERO CLEARANCE 44.2 If spacings between combustible material and the duct in which a duct heater is installed must be no less than a specified distance to prevent attainment of hazardous temperatures on that material, the heater shall bear a suitable warning marking to convey this information. See paragraph 36.6. 36.6 A duct heater rated 50 kilowatts (kw) or less shall be suitable for installation with zero spacing between the duct and combustible surfaces. A duct heater rated more than 50 kw may necessitate that such spacings be larger than zero. All Inducto duct heater control compartments. whether integral or remote, are provided with a piano type hinge on the longest cover dimension or on any side specified. All covers are provided with an approved latch requiring a tool to open and a pull ring to facilitate opening the cover. All covers over 48" long are provided with two latches and pull rings. Inducto Heaters Series "HF" are UL listed for zero clearance up to 1000 KW. 16 B - HEATER POWER CIRCUITRY See wiring diagrams for details of the various wiring systems mentioned below. All stages of a heater are of equal KW unless specified otherwise. For pricing of unequal stages, see Pricing Section. Page 16- ELECTRICAL DESIGN 5 - Power Wire Sizing: If a long run of wire is required or more than three wires are run in a conduit the allowable capacity on a given wire size must be reduced as per NEC requirements (see note 13 to NEC Table 310-16 and 310-18) MAXIMUM AMP LOAD ALLOWED ON VARIOUS WIRE SIZES FOR. FIELD WIRING TO DUCT HEATERS De-Rated 20% 1 - Single phase power circuits: Each circuit consists of a heating coil (or coils connected parallel) which cannot exceed 48 amp for over-current protection. A single stage heater may be controlled directly by a line voltage thermostat without using a controlling contactor if the heater rating is within the rating of the thermostat, the over-temperature protection controls and the fan interlock. Larger loads are controlled by contactors, S.C.R. controllers or load carrying step controllers. 2 - Balanced Three Phase Power Circuits: Each circuit cannot exceed 48 amp for over-current protection and consists of three (or a multiple of three) heating coils factory connected in delta or wye system at the factory's option. The load will be balanced (equal) among the three phases and the entire circuit is controlled as a unit and operates identically whether the power source is three or four wire. Therefore a neutral terminal is not furnished on balanced circuits. Each circuit is normally controlled by a contactor which in turn is controlled by a thermostat or step controller in the control circuit. TABLE 3 TABLE 4 Except From Table 3A - NEC Maximum Number of Conductors in Trade Sizes of Conduit or Tubing (Based on Table 1, Chapter 9) SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE 17 ELECTRICAL DESIGN - Page 17 TABLE 5 TOTAL AMPERAGE RATING CHART K.W. Rating B.T.U.H. 208 AMP Volts Rating 220 AMP Volts Rating 230 AMP Volts Rating 240 Volts AMP Rating 0.5 1.0 2.0 1,706 3,413 6.826 3.0 4.0 5.0 6.0 440 Volts AMP Rating 480 Volts AMP Rating 550 Volts AMP Rating 1 PH 3 PH 1 PH 3 PH 1 PH 3 PH 1 PH 3 PH 02.4 04.8 09.6 01.4 02.8 05.6 02.3 04.5 09.1 01.3 02.6 05.2 02.2 04.3 08.7 01.3 02.5 05.0 02.1 04.2 08.3 01.2 02.4 04.8 1 PH 3 PH 3 PH 3 PH 01.8 03.6 07.2 0.7 1.3 2.6 0.6 1.2 2.4 0.5 1.0 2.1 10,239 14.4 08.3 13.6 07.9 13.0 07.5 12.5 13,652 17,065 20,478 19.2 24.0 28.8 11.1 13.9 16.7 18.2 22.7 27.3 10.5 13.1 15.7 17.4 21.7 26.1 10.0 12.6 15.1 16.7 20.8 25.0 07.2 10.8 3.9 3.6 3.1 09.6 12.0 14.4 14.4 18.1 21.7 5.2 6.6 7.9 4.8 6.0 7.2 4.2 5.2 6.3 7.0 8.0 23,891 27,304 33.7 38.5 19.4 22.2 31.8 36.4 18.4 21.0 30.4 34.8 17.6 20.1 29.2 33.3 16.8 19.2 25.3 28.9 9.2 10.5 8.4 9.6 7.3 8.4 9.0 30,717 43.3 25.0 40.9 23.6 39.1 10.0 34,130 48.1 27.8 45.5 26.2 43.5 22.6 37.5 21.7 32.5 11.8 10.8 9.4 25.1 41.7 24.1 36.1 13.1 12.0 11.0 37,543 52.9 30.5 50.0 28.9 10.5 47.8 27.6 45.8 26.5 39.7 14.4 13.2 12.0 13.0 40,956 44,369 57.7 62.5 33.3 36.1 54.5 59.1 11.5 31.5 34.1 52.2 56.5 30.1 32.6 50.0 54.2 28.9 31.3 43.3 46.9 15.7 17.1 14.4 15.6 12.6 13.6 14.0 15.0 16.0 17.0 47.782 51,195 54,608 58,021 67.3 72.1 76.9 81.7 38.9 41.6 44.4 47.2 63.6 68.2 72.7 77.3 36.7 39.4 42.0 44.6 60.9 65.2 69.6 73.9 35.1 37.7 40.2 42.7 58.3 62.5 66.7 70.8 33.7 36.1 38.5 40.9 50.5 54.2 57.8 61.4 18.4 19.7 21.0 22.3 16.8 18.0 19.2 20.4 14.7 15.7 16.8 17.8 18.0 19.0 61,434 64,847 86.5 91.3 50.0 52.7 81.8 86.4 47.2 49.9 78.3 82.6 45.2 47.7 75.0 79.2 43.3 45.7 65.0 68.6 23.6 24.9 21.7 22.9 18.9 19.9 20.0 21.0 68,260 71,673 96.2 101.0 55.5 58.3 90.9 95.5 52.5 55.1 87.0 91.3 50.2 52.7 83.3 87.5 48.1 50.5 72.2 75.8 26.2 27.6 24.1 25.3 21.0 22.0 22.0 23.0 24.0 75,086 105.8 61.1 100.0 57.7 95.7 55.2 91.7 52.9 79.4 28.9 26.5 23.1 78,499 81.912 110.6 115.4 63.8 66.6 104.5 109.1 60.4 63.0 100.0 104.3 57.7 60.2 95.8 100.0 55.3 57.7 83.0 86.6 30.2 31.5 27.7 28.9 24.1 25.2 25.0 26.0 27.0 85,325 88,738 92.151 120.2 125.0 129.8 69.4 72.2 74.9 113.6 118.2 122.7 65.6 68.2 70.9 108.7 113.0 117.4 62.8 65.3 67.8 104.2 108.3 112.5 60.1 62.5 65.0 90.3 93.9 97.5 32.8 34.1 35.4 30.1 31.3 32.5 26.2 27.3 28.3 28.0 29.0 95,564 98,977 134.6 139.4 77.7 80.5 127.3 131.8 73.5 76.1 121.7 126.1 70.3 72.8 116.7 120.8 67.4 69.8 101.1 104.7 36.7 38.1 33.7 34.9 29.4 30.4 30.0 102,390 144.2 83.3 136.4 78.7 130.4 75.3 125.0 72.2 108.3 39.4 36.1 31.5 31.0 105,803 149.0 86.0 140.9 81.4 134.8 77.8 129.2 74.6 111.9 40.7 37.3 32.5 32.0 33.0 109,216 112.629 153.8 158.7 88.8 91.6 145.5 150.0 84.0 86.6 139.1 143.5 80.3 82.8 133.3 137.5 77.0 79.4 115.5 119.1 42.0 43.3 38.5 39.7 33.6 34.6 34.0 35.0 116,042 119,455 163.5 168,3 94.4 97.2 154.5 159.1 89.2 91.9 147.8 152.2 85.3 87.9 141.7 145.8 81.8 84.2 122.7 126.4 44.6 45.9 40.9 42.1 35.7 36.7 36.0 122,868 173.1 99.9 163.6 94.5 156.5 90.4 150.0 86.6 130.0 47.2 43.3 37.8 37.0 126,281 177.9 102.7 168.2 97.1 160.9 92.9 154.2 89.0 133.6 48.6 44.5 38.8 38.0 129.694 182.7 105.5 172.7 99.7 165.2 95.4 158.3 91.4 137.2 49.9 45.7 39.9 39.0 133,107 187.5 108.3 177.3 102.4 169.6 97.9 162.5 93.8 140.8 51.2 46.9 40.9 40.0 41.0 136,520 139.933 192.3 197.1 111.0 113.8 181.8 186.4 105.0 107.6 173.9 178.3 100.4 102.9 166.7 170.8 96.2 98.6 144.4 148.0 52.5 53.8 48.1 49.3 42.0 43.0 42.0 43.0 44.0 143.346 146,759 150,172 201.9 206.7 211.5 116.6 119.4 122.1 190.9 195.5 200.0 110.2 112.8 115.5 182.6 187.0 191.3 105.4 107.9 110.5 175.0 179.2 183.3 101.0 103.4 105.9 151.6 155.2 158.8 55.1 56.4 57.7 50.5 51.7 52.9 44.1 45.1 46.2 45.0 46.0 153,585 156.998 216.3 221.2 124.9 127.7 204.5 209.1 118.1 120.7 195.7 200.0 113.0 115.5 187.5 191.7 108.3 110.7 162.5 166.1 59.0 60.4 54.1 55.3 47.2 48.3 47.0 160,411 226.0 130.5 213.6 123.3 204.3 118.0 195.8 113.1 169.7 61.7 56.5 49.3 48.0 49.0 50.0 163,824 167,237 170,650 230.8 235.6 240.4 133.2 136.0 138.8 218.2 222.7 227.3 126.0 128.6 131.2 208.7 213.0 217.4 120.5 123.0 125.5 200.0 204.2 208.3 115.5 117.9 120.3 173.3 176.9 180.5 63.0 64.3 65.6 57.7 58.9 60.1 50.4 51.4 52.5 51.0 52.0 174.063 177.476 245.2 250.0 141.6 144.3 231.8 236.4 133.8 136.5 221.7 226.1 128.0 130.5 212.5 216.7 122.7 125.1 184.1 187.7 66.9 68.2 61.3 62.5 53.5 54.6 53.0 54.0 180,889 184.302 254.8 259.6 147.1 149.9 240.9 245.5 139.1 141.7 230.4 234.8 133.0 135.6 220.8 225.0 127.5 129.9 191.3 194.9 69.5 70.9 63.8 65.0 55.6 56.7 55.0 187,715 264.4 152.7 250.0 144.3 239.1 138.1 229.2 132.3 198.6 72.2 66.2 57.7 56.0 191,128 269.2 155.4 254.5 147.0 243.5 140.6 233.3 134.7 202.2 73.5 67.4 58.8 57.0 194,541 274.0 158.2 259.1 149.6 247.8 143.1 237.5 137.1 205.8 74.8 68.6 59.8 58.0 197,954 278.8 161.0 263.6 152.2 252.2 145.6 241.7 139.5 209.4 76.1 69.8 60.9 59.0 201,367 283.7 163.8 268.2 154.8 256.5 148.1 245.8 141.9 213.0 77.4 71.0 61.9 60.0 204,780 288.5 166.5 272.7 157.5 260.9 150.6 250.0 144.3 216.6 78.7 72.2 63.0 18 277 Volts AMP Rating Page 18. ELECTRICAL DESIGN TOTAL AMPERAGE RATING CHART (CONT'D) K.W. Rating B.T.U.H. 208 Volts AMP Rating 220 Volts AMP Rating 230 Volts AMP Rating 240 Volts AMP Rating 277 Volts AMP Rating 440 Volts AMP Rating 480 Volts AMP Rating 550 Volts AMP Rating 1 PH 3 PH 1 PH 61.0 208,193 293.3 169.3 277.3 3 PH 1 PH 3 PH 1 PH 3 PH 1 PH 3 PH 3 PH 3 PH 160.1 265.2 153.1 254.2 146.7 220.2 80.0 73.4 62.0 211,606 298.1 172.1 64.0 281.8 162.7 269.6 155.6 258.3 149.2 223.8 81.4 74.6 63.0 64.9 65.0 215,019 218,432 221,845 302.9 307.7 312.5 65.1 174.9 177.7 180.4 286.4 290.9 295.5 165.3 168.0 170.6 273.9 278.3 282.6 158.1 160.7 163.2 262.5 266.7 270.8 151.6 154.0 156.4 227.4 231.0 234.7 82.7 84.0 85.3 75.8 77.0 78.2 66.1 67.2 68.2 66.0 225,258 67.0 228,671 317.3 183.2 300.0 173.2 287.0 165.7 275.0 158.8 238.3 86.6 79.4 69.3 322.1 186.0 304.5 175.8 291.3 168.2 279.2 161.2 241.9 87.9 80.6 68.0 69.0 70.3 232,084 235,497 326.9 331.7 188.8 191.5 309.1 313.6 178.5 181.1 295.7 300.0 170.7 173.2 283.3 287.5 163.6 166.0 245.5 249.1 89.2 90.5 81.8 83.0 71.4 72.4 70.0 71.0 72.0 238,910 242,323 245,736 336.5 341.3 346.2 194.3 197.1 199.9 318.2 322.7 327.3 183.7 186.3 189.0 304.3 308.7 313.0 175.7 178.2 180.7 291.7 295.8 300.0 168.4 170.8 173.2 252.7 256.3 259.9 91.9 93.2 94.5 84.2 85.4 86.6 73.5 74.5 73.6 73.0 74.0 249,149 252,562 351.0 355.8 202.6 205.4 331.8 336.4 191.6 194.2 317.4 321.7 183.3 185.8 304.2 308.3 175.6 178.0 263.5 267.1 95.8 97.1 87.8 89.0 76.6 77.7 75.0 255,975 360.6 208.2 340.9 196.8 326.1 188.3 312.5 180.4 270.8 98.4 90.2 78.7 76.0 77.0 259,388 262.801 365.4 370.2 211.0 213.7 345.5 350.0 199.5 202.1 330.4 334.8 190.8 193.3 316.7 320.8 182.8 185.2 274.4 278.0 99.7 101.0 91.4 92.6 79.8 80.8 78.0 79.0 80.0 266,214 269,627 273,040 375.0 379.8 384.6 216.5 219.3 222.1 354.5 359.1 363.6 204.7 207.3 210.0 339.1 343.5 347.8 195.8 198.3 200.8 325.0 329.2 333.3 187.6 190.1 192.5 281.6 285.2 288.8 102.4 103.7 105.0 93.8 95.0 96.2 81.9 82.9 84.0 81.0 276,453 389.4 224.8 368.2 212.6 352.2 203.3 337.5 194.9 292.4 106.3 97.4 85.0 82.0 279,866 394.2 227.6 372.7 215.2 356.5 205.8 341.7 197.3 296.0 107.6 98.6 86.1 83.0 84.0 283,279 286,692 399.0 403.8 230.4 233.2 377.3 381.8 217.8 220.4 360.9 365.2 208.4 210.9 345.8 350.0 199.7 202.1 299.6 303.2 108.9 110.2 99.8 101.0 87.1 88.2 85.0 290,105 408.7 235.9 386.4 223.1 369.6 213.4 354.2 204.5 306.9 111.5 102.2 89.2 86.0 87.0 88.0 293.518 296,931 300,344 413.5 418.3 423.1 238.7 241.5 244.3 390.9 395.5 400.0 225.7 228.3 230.9 373.9 378.3 382.6 215.9 218.4 220.9 358.3 362.5 366.7 206.9 209.3 211.7 310.5 314.1 317.7 112.8 114.2 115.5 103.4 104.6 105.9 90.3 91.3 92.4 89.0 303,757 427.9 247.0 404.5 233.6 387.0 223.4 370.8 214.1 321.3 116.8 107.1 93.4 90.0 307,170 432.7 249.8 409.1 236.2 391.3 225.9 375.0 216.5 324.9 118.1 108.3 94.5 91.0 92.0 310,583 313,996 437.5 442.3 252.6 255.4 413.6 418.2 238.8 241.4 395.6 400.0 228.4 230.9 379.2 383.3 218.9 221.3 328.5 332.1 119.4 120.7 109.5 110.7 95.5 96.6 93.0 94.0 317,409 320,822 447.1 451.9 258.1 260.9 422.7 427.3 244.1 246.7 404.3 408.7 233.5 236.0 387.5 391.7 223.7 226.1 335.7 339.4 122.0 123.3 111.9 113.1 97.6 98.7 95.0 324,235 456.7 263.7 431.8 249.3 413.0 238.5 395.8 228.5 343.0 124.7 114.3 99.7 96.0 327,648 461.5 266.5 436.4 251.9 417.4 241.0 400.0 230.9 346.6 126.0 115.5 100.8 97.0 331,061 466.3 269.3 440.9 254.6 421.7 243.5 404.2 233.4 350.2 127.3 116.7 101.8 98.0 99.0 334,474 337,887 471.2 476.0 445.5 450.0 257.2 259.8 426.1 430.4 246.0 248.5 408.3 412.5 235.8 238.2 353.8 357.4 128.6 129.9 117.9 119.1 102.9 103.9 100.0 105.0 341,300 358,365 480.8 504.8 272.0 274.8 277.6 291.5 454.5 477.3 262.4 275.6 434.8 456.5 251.0 263.6 416.7 437.5 240.6 252.6 361.0 379.1 131.2 137.8 120.3 126.3 105.0 110.2 110.0 375,430 528.8 305.3 500.0 288.7 478.3 276.1 458.3 264.6 397.1 144.3 132.3 115.5 116.0 120.0 392,495 409,560 552.9 576.9 319.2 333.1 522.7 545.5 301.8 314.9 500.0 521.7 288.7 301.2 479.2 500.0 276.7 288.7 415.2 433.2 150.9 157.5 138.3 144.3 120.7 126.0 125.0 130.0 135.0 426.625 443,690 460,755 601.0 625.0 649.0 347.0 360.9 374.7 568.2 590.9 613.6 328.0 341.2 354.3 543.5 565.2 587.0 313.8 326.3 338.9 520.8 541.7 562.5 300.7 312.7 324.8 451.3 469.3 487.4 164.0 170.6 177.1 150.4 156.4 162.4 131.2 136.5 141.7 140.0 477,820 673.1 388.6 636.4 367.4 608.7 351.4 583.3 336.8 505.4 183.7 168.4 147.0 145.0 494,885 697.1 402.5 659.1 380.5 630.4 364.0 604.2 348.8 523.5 190.3 174.4 152.2 150.0 511,950 721.2 416.4 681.8 393.7 652.2 376.5 625.0 360.9 541.5 196.8 180.4 157.5 155.0 160.0 165.0 529,015 546,080 563.145 745.2 769.2 793.3 430.2 444.1 458.0 704.5 727.3 750.0 406.8 419.9 433.0 673.9 695.7 717.4 389.1 401.6 414.2 645.8 666.7 687.5 372.9 384.9 396.9 559.6 577.6 595.7 203.4 210.0 216.5 186.4 192.5 198.5 162.7 168.0 173.2 170.0 580,210 817.3 471.9 772.7 446.1 739.1 426.7 708.3 409.0 613.7 223.1 204.5 178.5 175.0 597,275 841.3 485.8 795.5 459.3 760.9 439.3 729.2 421.0 631.8 229.6 210.5 183.7 180.0 614,340 865.4 499.6 818.2 472.4 782.6 451.9 750.0 433.0 649.8 236.2 216.5 189.0 185.0 190.0 631,405 648,470 889.4 913.5 513.5 527.4 840.9 863.6 485.5 498.6 804.3 826.1 464.4 477.0 770.8 791.7 445.1 457.1 667.9 685.9 242.8 249.3 222.5 228.5 194.2 199.5 195.0 665,535 937.5 541.3 886.4 511.8 847.8 489.5 812.5 469.1 704.0 255.9 234.6 204.7 200.0 682,600 961.5 555.2 909.1 524.9 869.6 502.1 833.3 481.1 722.0 262.4 240.6 210.0 SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE 19 ELECTRICAL DESIGN - Page 19 As standard practice balanced three phase circuits will be furnished for three phase power unless single phase circuits from three phase power are specified. 2 - Overcurrent Protection: The NEC par. 424-22 states: (b) Resistance Elements. Electric space heating equipment employing resistance-type heating elements rated more than 48 amperes shall have the heating elements subdivided. Each subdivided load shall not exceed 48 amperes and shall be protected at not more than 60 amperes. (c) Overcurrent, Protective Devices. The overcurrent protective devices specified in (b) above shall be: (1) factory-installed within or on the heater enclosure or provided as a separate assembly by the heater manufacturer; (2) accessible, but shall not be required to be readily accessible; and (3) suitable for branch-circuit protection. Where cartridge fuses are used to provide this overcurrent protection, a single, disconnecting means shall be permitted to be used for the several subdivided loads. Fuses and circuit breakers are available with the heaters, to meet the above requirements, either built in the terminal box or built in a panel for remote mounting (see "D - Remote Control Panels"). The overcurrent protection (fusing or circuit breakers) must be sized at least 125% of the circuit load it protects. For example, 60 amp fuses are required for a 48 amp load. The maximum KW allowed per various voltages is shown in table 6. For heaters drawing 48 amp or less total load, the branch circuit fusing at the distribution panel usually meets the NEC requirements, however, supplementary fusing for each stage within the heater can be furnished if specified. As standard practice, small stages will be grouped to a maximum of 48 amp and fused as one circuit. This conserves space and is more economical while meeting all NEC requirements, however, each stage will be protected separately when specified. Dual element fuses are available when specified. See Pricing Section. 3 - SINGLE PHASE CIRCUITS FROM THREE PHASE POWER SUPPLY If the power supply to the heater is three phase and the heater circuits are to be controlled by: load carrying switches of a step controller, single phase S.C.R. controllers, or similar load carrying device, single phase circuits from three phase power must be specified. Whether the power supply is three or four wire system must also be / specified. For three wire systems each circuit is connected between alternate pairs of phases using the delta configuration. When any multiple of three circuits are heating, the load will be balanced. For four wire systems each single phase circuit is connected between one phase and the neutral using alternate phases for consecutive circuits. NOTE: Some SCR controllers or load carrying step controllers cannot accept the automatic over-temperature limits in a control circuit to de-energize the heater immediately should an over-temperature condition occur. If this is the case, magnetic contactors, which are controlled by the primary, automatic, over-temperature cutouts, must also be connected in the load circuit to de-energize the heater preventing over-heating. C - BUILT-IN COMPONENTS 1 - Internal Heater Wiring: All factory wiring is UL labeled. 105°C thermoplastic insulated, copper appliance type wire. As a result of UL testing the following has been established as the maximum load per wire size on factory wiring within the heater (does not apply to field wiring): 12 AWG 30 Amp maximum 10 AWG 40 Amp maximum 8 AWG 48 Amp maximum MAXIMUM KW PER CIRCUIT FOR OVERCURRENT PROTECTION (48 Amp) Two or more circuits may be paralleled to make one heating stage. FIGURE 2 - Typical Fuse block TABLE 6 20 Page 20- ELECTRICAL DESIGN INSTRUCTIONS RECOMMENDED PROCEDURE FOR ALUMINUM TERMINATIONS GENERAL To help guard against overheating, the following procedure is recommended when connecting aluminum wire. PROCEDURE Step 1. Strip the wire of its insulation to the desired length without ringing or nicking the wire. Step 2. Wire brush the stripped portion of conductor thoroughly. Step 3. Thoroughly coat stripped conductor with oxide inhibiting compound. (Two recognized compounds are Penetrox A and Alnox-UG. There may be others available which will do equally well.) Step 4. Insert the conductor into the connector making certain all strands are contained and tighten the connector screws securely. This operation should result in the compound oozing out from between the individual strands of the conductor. If this does not happen, this is an indication that an insufficient quantity of compound was used. Step 5. Wipe excess compound from area adjacent to connection because some compounds contain metallic particles and could reduce the dielectric strength of the insulating materials employed. FIGURE 3 -Typical Circuit Breaker 3 - Power Supply Connections: A heavy duty terminal block, or blocks, are provided in Inducto Duct Heaters for each field wiring connection for both control and power circuits. The number of power supply circuits required to a duct heater may depend on the components that are built in. See built-in fusing and contactor sections, IV-C-2 and IV-C-4 for an explanation of our standard practice. All field connection terminal blocks are designed to accommodate either copper or aluminum conductors as required by NEC and UL 1975. 4 - Built-in Magnetic Contactors: For use as primary controlling contactors and for secondary (backup) contactors (see secondary protection). Contactors are built-in only when specified. One, two, three and four pole are available with ratings as shown in figures 5, 6, and 7 and with holding coil voltages of 24, 120, 208/240, or 277V. The holding coil data, symbol and part number (where applicable) are also listed with the figure. All are UL listed as control components, having successfully passed the 100,000 cycle test under 150% of full rated amp load. The NEC requires that Duct Heater Controlling Contactors shall be accessible. In the definite purpose line the different voltage coils are easily interchangeable among all the sizes used. When controlling contactors are built in without built-in over-current protection, a power line FIGURE 4 . Typical Power Terminal Block Special Feature - When several sub-circuits are required to be fed from one main power supply terminal, a bus bar type terminal block is used to eliminate the problems associated with having multiple wires under one lug. SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE 21 ELECTRICAL DESIGN - Page 21 terminal block will be provided for each group of stages (or stage) not exceeding 48 ampere total, keeping to a minimum the number of field installed supply circuits required, while allowing for proper fusing in the field as required by both UL standards and the NEC. This means that heaters 48 amp or less will require only one power supply circuit. However, when specified that. each stage is to be field wired with a separate circuit for individual fusing, a terminal block is provided for each stage for field connections. STANDARD USAGE PRACTICE Our standard practice when contactors are built in, for controlling and/or backup duty, is to de-energize the circuit only. That is, to use contactors that will open only enough power lines to interrupt the flow of current to that stage being controlled. Contactors must be used that will disconnect all ungrounded conductors of the circuit in some cases, such as: (a) local or state requirements, (b) if the control or thermostat is marked with "OFF," (c) by engineering specification. If any of these conditions exist, disconnecting type contactors must be specified when ordering. For contactor pricing refer to Pricing Section. FIGURE 6 - THE SINGLE POLE CONTACTOR is a totally enclosed unit with a rating of 18 amps resistive and 2 HP inductive at 250 volts. Coil Data: 10 VA inrush - 5 VA holding MERCURY CONTACTORS: This type of contactor should be used in applications where minimum noise is a definite factor or where rapid cycling control systems are used. These units are rugged with all moving parts totally sealed within a tube, eliminating all exposed arc. All mercury contactors, must be installed in an upright position, therefore the direction of air flow through the duct must be specified when specifying this type of contactor. See Pricing Control circuit voltages available are 24, 120, 208/240, and 277 volt. FIGURE 5 DEFINITE PURPOSE CONTACTOR: Available in 25,30,40 and 50 amp resistive rating with heavy duty contacts and encapsulated coil which resists oil, dirt, moisture and mechanical damage. Holding Coil Coil Voltage 24V 110V 208/ 277V 480V 240V Contactor symbol VA inrush VA holding Replacement part No. 24 77 8.6 02 77 8.8 03 77 8.8 55-2G24 55-2G2 55-2G3 19 77 8.8 FIGURE 7 - Typical Three Pole Mercury Contactor Series BF BF BF BFC BFC BFC 04 77 8.8 55-2G19 55-2G4 22 No. of Poles 1 2 3 1 2 3 Holding Coil Data Inrush VA 9.0 18.0 38.0 10.0 25.0 40.0 Holding VA 6.0 12.0 25.0 6.5 13.0 28.0 gives for longer life of the control. The heater elements are controlled simultaneously, no sequencing of steps, which means there is no possibility of air stratification. Several slave controls can be used with one master control and thermostat. B - Description: These UL listed solid state proportional controllers consist of a triac assembly mounted on a heat sink. These specially designed SCR's have the triac assembly mounted inside the terminal box and the heat sink is attached to the outside of the terminal box. The heat sinks are in the open air where there is good convection cooling, keeping the inside of the terminal box at a normal temperature. Inducto heaters with built-in SCR's can be used with the air entering on either side. A special UL listed solid state thermostat must be furnished when ordering any combination of SCR's. Power output is controlled from 0 to 100% and is infinitely variable in direct proportion to thermostat output. All elements in the heater are controlled simultaneously avoiding problems of air stratification. See Pricing Section. Page 22 - ELECTRICAL DESIGN 5 - Fan Interlock Options: Effective January 30, 1974, all Inducto heaters must be furnished with a type of fan interlock. The Inducto standard will be a differential pressure switch. A - Differential Pressure Switch. (Standard): The differential pressure switch is available built-in to the terminal box compartment UL approved. This has become a very popular method. This is an excellent application when constant fan is used. B - Electrical Interlock: A one pole contactor interlock will be built in, wired to energize the fan circuit when the first stage of the heater is energized. (See wiring diagrams number E2-A, B & C). For pricing refer to Pricing Section. FIGURE 8 Typical Differential Pressure Switch Thermistor Type Thermostat 6 - SCR Controllers A - Application and Advantages: These solid state proportional controllers are ideal for application in schools, libraries, offices and hospitals where noise is a factor. Since they are all solid state there are no moving parts, which C - Thermostat: A wall mounted vertical or horizontal thermistor type thermostat model 701-1 with manual "On" and STBY (stand-by) must be used with each Master SCR. Thermostat range is 65°F to 85°F proportional band is 2°F. (Full heat demand will actuate on a 2°F change.) Any smaller change will cause a proportionately smaller SCR output. Accuracy of thermostat is -± 1°F. Remember: No other commercial thermostat can be used. For applications thermostat or a factory. requiring either a duct pneumatic system, consult D - Safety Contactor: Safety contactors UL listed must be installed in front of and in line with the SCR's unless the automatic reset thermal cutout can carry the load. All three phase heaters must be furnished with a safety contactor. FIGURE 9 Duct Heater SCR - (Solid State) SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE 23 Any single phase heater exceeding the following ratings must have safety contactors. AUTOMATIC ELECTRICAL DESIGN - Page 23 2.5KW @ 277V, Single Phase THERMAL CUTOUT 2.5KW @ 240V, Single Phase R ATINGS 2.1KW@ 208V,Single Phase 1.8KW@ 120V, Single Phase Control Voltage: This SCR system generates its own control voltage for operation of thermostat. Safety contactors holding coils can be operated direct from line voltage up to 277 volts, single phase when 480 volt three phase is required a step-down transformer must be furnished. 7 - Disconnect Switches: The National Electric Code states that there must be a disconnecting means at or within site of the controlling means. Disconnect switches can be field supplied or can be built into the heater integral control panel or remote control box. We offer two types of disconnect switches. Door interlock type (fig. 11) or toggle type without door interlock (fig. 11 a). Both devices meet the requirements of the N.E.C. Door interlock switches are snap-action type with the operating handle mounted in the hinged cover and interlocked to open only when in the off position. Toggle type switches are mounted on the side of the control panel and kills all power in the heater when in the off position. 8 Micro De-energizing Switch: Electrical de-energizing switch for control circuit. Plunger type switch wired into control circuit of heater to automatically de-energize the control circuit when door is opened. Switch is single pole double throw rated at 15 amps up to 480 v non-inductive; 1/8 HP at 125 volts, 1/4 HP at 240 volts inductive. Alternate switch is available for line volts over 480. Switch is rated at 10 amps up to 600 volts non-inductive and 6 amps at. 115 volts; 3 amps at 230 volts; 1.5 amps at 480 volts and 1.2 amps at 575 volts inductive. Both UL and NEC require that the contactors be the disconnecting type when this type of switch is used. This switch does not serve as the disconnect switch as required by the NEC. See Pricing Section. FIGURE 12 - Typical Pressure Type Micro Switch 9 - UL and NEC Safety Requirements: (a) Primary over-temperature protection (cutouts) Standard Disc Type: As standard practice all Inducto Duct Heaters incorporate, as part of the basic heater, one or more disc type, automatic resetting temperature limiting devices (Fig. 13). When a higher than normal temperature condition occurs within the heating area and the bi-metal disc reaches 170°F. the cutout opens de-energizing the heater. After cooling, the heater is automatically energized to continue service. The limit control is a UL listed temperature limiting component having passed the 100,000 cycles of operation test under 150% of full rated load. It may be wired in the power circuit of single phase heaters not exceeding its rated capacity and in the control circuit, for pilot duty, on larger single phase and all three phase heaters. The resistive rating is 25 amperes and the pilot duty rating is 125VA at 120, 240 or 277 Volts AC. FIGURE 11 A • Typical Toggle Disconnect Switch FIGURE 11 - Typical Disconnect Switch with Operating handle. 24 Page 24 - ELECTRICAL DESIGN (1) This type of secondary over-temperature protective device has to be replaced to reactivate the heater following correction of the problems discussed above. Two types are available. They may be wired in line (load carrying) up to their rated capacity of 48 amps, using enough cutouts to de-energize the heater. They may also be wired for pilot duty using one for the entire heater to control backup contactors which are independent of the primary controlling contactors. (See backup contactors below.) FIGURE 13 -Disc Type FIGURE 14 - Capillary Type Capillary Type Cutouts (Special): On heaters for ducts exceeding 10 feet in width a capillary type automatic resetting limit control is required. In addition, if the duct is also over 40 inches in height two are required. This device has a capillary temperature sensing element which is mounted along the heating element enclosure giving protection across the entire width of the duct. It will be used on smaller duct heaters only when specified. The application and rating is identical to the disc type described above. This cutout is a "fail safe" type control. For pricing of the capillary type limit control see Pricing. Secondary Temperature Limit Controls - Disc Type (Replaceable) Wired in a power circuit on single or three phase heaters to de-energize the heater stage on over-heating. Rated at 48 AMP up to 600 volt. Temperature to open 210 degrees F. (b) Secondary over-temperature protection (backup system) The edition of the NEC states in section 424-64 (second paragraph): "In addition" (to the automatic primary limit controls) "an integral, independent, supplementary control, or controllers, shall be provided in each duct heater which will disconnect a sufficient number of conductors to interrupt current flow. This device shall be manually resettable or replaceable." The secondary protection (backup system) is always set at a higher temperature (210°F) than the automatic primary limit controls, therefore it should only operate when both an over-temperature condition occurs and the primary system fails due to frozen contacts, etc. Inducto Duct Heaters are available with the following two systems, UL listed, to meet the above requirements. (2) Back up contactors with pilot duty manual reset. Reset is wired in series with backup contactor to deenergize heater. SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE 25 ELECTRICAL DESIGN - Page 25 When backup and controlling contactors are built-in, the stages may be grouped to a maximum of 48 amps per circuit, before being wired through the backup contactors. When the stages are small enough to allow grouping into a circuit of 48 amp maximum, fewer backup contactors are required to de-energize the heater. EXAMPLE: A three phase heater with three stages of 16 amp each will be grouped into one circuit of 48 amps on the line side of the controlling contactors and will require only two contacts (50 amp size) on the backup contactor to de-energize this heater. The above procedure (grouping) will not apply when it is specified that each stage is to be field wired to a separate supply circuit. For maximum KW per circuit (48 amp) see Table 6. NOTE: The maximum voltage allowed on the manual resettable cutouts is 480 volt on the disc type and 277 volt for the capillary type; therefore on heaters using higher line voltages, a separate voltage source for the backup control circuit must be supplied. This may be either from a built-in transformer or from a remote supply and must be specified. Both UL and the NEC require only de-energizing type contactors for backup service. For pricing of backup contactors refer to de-energizing type contactor. Refer to Pricing. Disc Type: This device uses a bimetal disc to sense over-temperature conditions and is mounted through the terminal compartment. It is recommended for use on heaters to be installed in ducts up to 10 feet in width. HF series heaters are designed for manual resettable disc-type cut-out (load carrying) application. Available are one-pole and two-pole manual 48 amp maximum rated to 600 volts AC. The two-pole manual resettable will accommodate 96 amp on single phase application and 48 amp on three phase application. For selection of manual resettable disc-type cutouts, refer to pricing. FIGURE 17 - Capillary Type Manual Resettable Cutout - Capillary Type: This device is the ultimate in over-temperature protection and is recommended to be used on all heaters over six feet in "W" dimension. It is required on all heaters over 10 feet "W" dimension. The temperature sensing capillary is mounted along the top inside of the element enclosure and down stream from the elements; therefore, the air flow direction must be specified when ordering this unit. Normally only one of this type cutout is used per heater. If the heater load exceeds its rated capacity then the cutout should be used for pilot duty in conjunction with backup contactors. Refer to Pricing. Backup Contactors: When a capillary Manual Resettable cut-out, described above, is to be used as the secondary protection, and is not wired in the line to directly de-energize the heater, then one must be used, wired for pilot duty, controlling backup contactors. Backup contactors are in addition to, and independent of, the primary controlling contactor or other device, and are controlled by the manual resettable cutout only. They are wired in the line to deenergize the heater when an over-temperature condition causes the manual resettable cutout to cycle off. They may be either built-in or remote. NOTE: Backup contactors must be wired so they will not cycle off and on by the thermostat. FIGURE 18 - Typical Control Transformer 10 - Built-in Control Transformers: When the control voltage is different duct heater power voltage, a step-down 26 from the Page 26- ELECTRICAL DESIGN 12 - Indicator (pilot) Light: Neon lights, mounted through the front door panel of the control box can be wired to indicate when: (1) One stage is on (2) Each stage is on (3) An over-heating condition occurs. Each light is marked as to the function it indicates. For available circuitry see wiring diagram numbers E7-A, B, C, D, E, and F. The lights are mounted on the front door panel for easy viewing and are available for 120, 208/240, 277 or 480 volts. Refer to Pricing. transformer may be built-in to supply the correct voltage thereby eliminating the task of running a separate supply to the heater for the control circuit. The transformers are UL listed and are available with primary and secondary voltages and sizes as listed (Refer to Pricing). The VA rating required for a given quantity of definite purpose type contactors is also listed along with prices. If controlling contactors are not built-in, both the primary and secondary of the transformer are wired to a terminal block for field connection as required on the job. Unless specified otherwise the primary voltage will be the same as the heater power supply. Either or both the secondary and primary can be fused when specified. If a manual resettable cutout and backup contactors are being used and the heater line voltage exceeds the voltage rating of the cutout then the control transformers should be sized to, carry both the controlling and backup contactors or a separate supply furnished for the backup control circuit. Refer to Pricing. 11 - Time Delay Relays When a positive time delay is needed between the "on" cycle of consecutive stages to prevent them from coming on simultaneously a time delay relay is available built-in and factory wired. For control voltages of 24, 120, 208, 240 and 277 the 600 type is used, wired as shown in diagram E5-B. The 600 type gives approximately a 25 second delay in the "on" cycle, but is wired to turn the heat off immediately when thermostat is satisfied, however a few seconds are required for the delay relay to recycle off in order to repeat the on delay sequence. Refer to Pricing. FIGURE 20 - Application of indicator light ana pilot switch. 13 - Pilot Switch: A single pole toggle switch is available, which can be factory wired to prevent operation of a heater stage or the entire heater (see diagram number E8 A & B). The pilot switch can be used in control circuits of 24, 120, 208/240 or 277 volts. Note: Both UL and NEC require that disconnecting type contactors be used when a pilot switch is used. This pilot switch does not serve as the disconnect switch as required by the NEC. Refer to Pricing. FIGURE 19 - Time Delay Relay type 24A11. Switch rating 25 amp, 250 voltage maximum. Timer draws .15 amp for anticipator setting. FIGURE 21 -Pilot Relay Rating: 8 Amp resistive; 3 Amp at 125 volt and 1.5 amp at 250 volt inductive. SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE 27 ELECTRICAL DESIGN . Page 27 14 - Pilot Relay: In some cases when using a 24 volt control system the VA load of several heavy duty contactors may exceed the capacity of the thermostat or the low voltage transformer. In such cases a pilot relay can be built in, controlled by the 24 volt circuit to switch line voltage (250 volt maximum) which operates the heavy duty contactors. Refer to Pricing Section. 15 - Pneumatic-Electric (P.E.) Switches: When a pneumatic-control system is used, P.E. switches are required to control the heater directly (load carrying) or to operate the controlling contactors of the duct heater (pilot duty). The P.E. switches, may be built in and factory wired. Inducto offers a number of P.E. switches that can be purchased and installed from our own stock. This application is UL approved and carries the standard one year warranty. Refer to Pricing Section. 16 -Step Controllers - Built in or remote. A - Electric Step Controllers: This built-in modulating electric step controller was developed especially for use in duct heaters and has a 150ºF ambient temperature rating. Standard time cycle for 10 switches to come on is 13 minutes. Built-in recycle relay prevents entire load from coming on at once after power failures. Switches are rated for pilot duty only (up to 240V) and must be used to control contactors. Specify holding coil voltage of 120V, 208V or 240V. For 480V line voltage applications, specify a 480V/120V transformer. Built-in transformer provides 24V for thermostat circuit only not for contactor holding coils. Minimum terminal box height is 12". Use T921A or T991A thermostat or equivalent. Should power for the step controller be furnished from the duct heater control transformer add 25VA to the required transformer capacity. NO. STEPS CATALOG NUMBER NUMBER OF STEP CONTROLLERS SUPPLIED 2-5 S984D1023 1 6-10 S984F1018 1 11-15 S984J+S984D 2 16-20 S984J+S984F 2 FIGURE 22-A Typical P.E. Switch A common practice has been for the controls contractor to send the switches to the factory for wiring and mounting. This leaves only the tubing connections and adjustment to be done in the field. P.E. switches supplied by others are not covered in the Inducto warranty, but if selected from the following list the heater will bear the UL label. Check the factory for additional listing. Perm Controls Model 6270, 6272, P10-BC,-BH,-FC, P67-AA, -CA, -EA, -FA Honeywell Model P658-A, -B, Model L404-A, -B, -C, -D, -F, P643A, P654A. L604A Robertshaw Model R423, R422, R424 Powers Model 134-1450, 134-1451, -2, -4, -5, -6, 251 Johnson Service Model G-270, -271, P7100, P7200, -7221 Mercoid Model AP-2. .3. -4, -26, -36, -54. -153 Barber Coleman Model PC-126,-127,-131,-132,-111,-141,-151 See wiring diagrams Figure E-6 for Pilot Duty and E-27 for load carrying systems. Refer to Pricing Section. FIGURE 23 - Electric Step Controller B - Thermostats Suggested for use with above electric step controllers. ROOM TYPE T921A (Modulating) FIGURE 24 Catalog Number T921A 28 Range Voltage 56-84ºF. 24V Only Throttling Range V½ºF. Type Room Page 28- ELECTRICAL DESIGN Catalog Number T991A Range Voltage Throttling Range Type 0-100°F. 24V Only 2½°F. Duct Electronic Step Controller 100% Solid State Operation — Operation typical of temperature regulation is as follows: Heating: As the temperature drops below the setpoint, the first stage heating circuit is energized. If the temperature continues to drop, the second, and subsequent, heating circuit(s) will be engaged. When the temperature rises above the "pull-in point" for a stage, that stage drops out. Time delay between stages assures sequencing of stages, in order, regardless of demand requirements. Sequencer re-programs to start (deadband) on power failure. Features Solid State circuitry. Printed circuit wiring Automatic changeover between mode function (heating and cooling) Time delay between stages assures sequencing of steps, regardless of demand. Re-programs to start through first stage on power failure. Thermistor sensing or 0-135 ohm input. Wall thermostat may be horizontally or vertically mounted. Senor may be wall mounted, or remote mounted. Remoted setpoint and/or sensor location available. Setpoints and deadband field adjustable. Unlimited selection of differential between stages and deadband range features. SPECIFICATIONS/ELECTRICAL Input Voltage 19.-29 VAC Current (Logic) 150 MA Current (Load) 1 Amp/Stage Furnished w/ 4½" bulb + 60" capillary tubing C - Pneumatic Step Controller: These step controllers are used for sequence control of electric duct heaters and other devices. The basic unit consists of a series of switches, cam operated by a common drive shaft, driven by a pneumatic actuator, all mounted on a common base. The switches are enclosed with a metal cover. An external pointer indicates the shaft position thru 180° from full "on" to full "off". Switches are factory set for normal operation and cams can easily be field adjusted. Switch differential is fixed with 5 angular degrees minimum. The switch rating is 20 amperes at 120, 250 and 480 volts AC, 1 HP at 125V and 2 HP at 250V. The power required for the SP-300 series or equivalent is 0-15 PSI air supply. Typical pneumatic thermostats are available to operate this controller. For pricing see Pricing Section. Check the factory for additional listing. Output Voltage Current Range of Setpoint Range Limits Same as input 1 Amp/Stage 20 °F 0°to125°F THERMISTOR INPUT Adjustment/Settings Factory Min. Max. Deadband 2°F 1°F 15 °F Pull-in between stages 1.5 °F 0.5 °F 6°F+ Hysteresis (pull-in/ drop out) 1.0°F Not field adj. 0-135 OHM INPUT Adjustment/Settings (On Application, consult factory) Operating Temperature - 15°F to 140°F Input Signal Standard 10K Optional ("A" suffix) 0-135 ohm FIGURE 26 Pneumatic Step Controller SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE 29 - CONTROL THERMOSTATS - ELECTRICAL DESIGN . Page 29 CATALOG NUMBER TYPE TEMP. RANGE VOLTAGE AMPERE RATING STAGES NO. ACTION 1A22 Room 50-90ºF 125-250277V. 22 1 HT. Bimetallic TJT-120 Room 60-90ºP 24V. — 1 HT. Bimetallic 1F30-910 Room 45-90ºF 25V 1 HT. Mercury Adj. Anticipator 0.15 to 1.0 A. ½ º Differential IF 56-301 Room 45-90ºF 25V — 1 HT. Mercury HTG.Adj.: 0.15 to 1.0A. Cooling: 0 to 1.5 A. 1C71-51 Room HT-50-85ºF CL55-90ºF 25V — 2HT. 1CL. Mercury HTG. Adj.: 0.15 to 1.0A. Cool Fixed: 0 to 1.5 A. 1C72-101 Room 50-85ºF 25V — 2HT. Mercury Adjustable 0.15 to 1.0A T675A1417 Duct 55-175ºF 120-240V 8 A.@ 120V 5.1 A.@ 240V 1 HT. Hydraulic 5' Copper Capillary ½ x3-9/16 Bulb Adj. Diff.: 3.6 to 12ºF T675A1029 Outdoor Bulb 0-100ºF 120-240V 8A@ 120V 5.1 A @ 240V 1 HT. Hydraulic M7M Room 35-90ºF 125-250277V 22A@ 125-250V 18A@277V 2HT. Bimetallic M7M-TP Room 35-90ºF 125-250277V Ditto 2HT. Bimetallic M7-TP Room 35-90ºF 125-250277V Ditto 1 HT. Bimetallic TC-282 Remote Bulb 10-90ºF 24-240V 12A@ 120V 6 A @ 240V 1600VA 3 SPDT Hydraulic Adj.Diff. 2-7ºF. Bet. Stages 0-20ºF 6' Cap. Lockable Knob L6018D-1004 Remote Bulb 55-85º F Ditto 2 SPDT Hydraulic Stage Diff. 2ºF. Interstage Diff. 4½ºF,5½' Cap. T42H-1081 Room 40-80ºF Ditto 2 HTG. Mercury Stage Diff. 1ºF.Interstage Diff. 1-5ºF. T42M-1031 Room 40-80ºF Ditto 3 HTG. Hydraulic Stage Diff 2ºF,Interstage Diff. 2ºF. 8A @ 120V 5.1 A @ 240V 1600 VA 1 A ® 240V 0.5 A @ 240V Ditto 1A22 FEATURES Load Carrying Snap Action Adj. Anticipator 0.3 to 1.0 A. 20' Copper Capillary ½ x 4-3/16 Bulb Adj.Diff.: 3 to 10ºF ½ºF Diff. 1½º Bet. Switches ½ºF Diff. 1½º Bet. Switches Tamper Proof ½ºF.Diff. 4 to 6 cycles/hour. Tamper Proof TJT-120 1F30-910 T675A-1540 T675A-1565 L6018D-1004 1C71-51 1C72-101 1F56-301 M7M M7M-TP M7-TP TC-282 T42M T42H 30 Page 30 - ELECTRICAL DESIGN E - REMOTE CONTROL PANELS In some applications the required components cannot be built in the duct heater terminal box because of space limitations, inaccessibility, etc. In this case some, or all, of the components can be mounted and factory wired internally, as applicable, in a panel for remote mounting. All terminals are marked to clearly indicate the field connections between the panel and the heater. The panel is of the same construction as the heater terminal box and the same components will be used as previously described in this catalogue for use in the Raywall duct heater. The required controls are controlling contactors, overcurrent protection, back up contactors (if used as the required backup system), and all must be supplied by the heater mfg. as required by UL and NCC. Heater and panel will be completely coordinated, ie: circuit sizing, terminal markings, etc., and a wiring diagram provided showing inter connections between components. The panel will be UL listed with the same controls and combinations as the heater with integral controls. Components that may be installed in remote panels are as follows: Controlling contactors Backup contactors Transformers SCR units Fusing or circuit breakers P.E. switches Disconnect switches Pilot lights Pilot switches Step controllers, program switches FIGURE 27 A Typical Remote Panel SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE 31 COPYRIGHT 1983 INDUCTO/MARKEL PRODUCS CO. 32 EEF FORM #C91181 Heater Tag Qty. Model No. Total Kw POWER Volts Phase Control Circ. Volts No. Of Stages KW Per Circ. Direction Of Air Flow Insert Flange Capillary Automatic Reset H Not approved Approved as noted Approved _______________________________ _______________________________ _______________________________ _______________________________ _______________________________ _______________________________ NOTES:_________________________ REMOTE CONTROL ENCLOSURE Fusing Fusing Dual Element Circuit Breaker Fused Disconnect Switch Unfused Disconnect Switch Dust Proof Enclosure 80/20 'A' Elements Derated Elements Protective Screen Time Delay Cover Interlock Switch Pilot Lights Pilot Switch Internal Duct Insulation ____ inch Aluminized BOTTOM INSERT CONTROL BOX De-energizing Contactor Disconnecting Contactor Mercury Contactor Electric Step Controller Pneumatic Setp Controller SCR Controller P.E. Switch Transformer w/pri. Fusing Transformer w/pri. & sec. Fusing Differential Pressure Switch Fan Interlock Relay Replaceable Over Temperature Protection Disc Type Capillary Manual Reset CHECK AS REQUIRED: INTEGRAL (Installed only when specified) W Healer Type Duct Size The following information is required: Quantity, KW, voltage, phase, number of circuits, controls and control volts, metal to metal duct size. Item INDUCTO DUCT HEATER SUBMITTAL OPEN COIL * * 'E' DIM. IS STANDARD 4½ " or 6 "½MAX. o r 9 ½" MAX. FOR DISCONNECT SWITCHES CONTRACTOR_____________________________________ ENGINEER ________________________________________ ARCHITECT _______________________________________ CUSTOMER _______________________________________ PROJECT_________________________________________ AGENT___________________________________________ INDUCTO/MARKEL INDUCTO HEATERS MARKEL PRODUCTS COMPANY JOHNSON CITY, TENNESSEE 37601 C B A 1. M, B, C, A. E, D, F, and G dimensions depend upon the heater design and will be determined by the factory. If any of these dimensions are critical, they must be specified under "Notes". 2. All heaters are furnished standard with Disc Type High Temperature Cut Outs (HTCO), Wiring and Terminal Strips. 3. Control panel extends on entering airside of element frame unless otherwise specified. 4. Advise details of duct insulation, Thickness, internal, external, etc. M *Heatd Page 31 Page 80 Markel Products Company Commercial Division P.O. Box T CRS Johnson City, TN 37601 615/282-5440 ORDER AND PRICING FORM 93061 P.O. DATE:___________________ PRICED BY:__________________ PAGE____OF___ INVOICE SHIP TO P.O. NUMBER ____________________________________ TAG JOB: ________________________________________ TAG TAG ITEM: _________ QTY. ____ _________ _________ ITEM: _________ QTY. ____ _________ _________ TOTAL KW _______POWER VOLTS_______PHASE_______ CONTROL VOLTS______________ NO. OF STEPS________ HEATER TYPE _________________ I = INSERT F = FLANGED DUCT SIZE W____ x H_____ OUTSIDE DIM. TOTAL KW _______POWER VOLTS_______PHASE_______ CONTROL VOLTS______________ NO. OF STEPS________ HEATER TYPE _________________ I = INSERT F = FLANGED DUCT SIZE W____ x H_____ OUTSIDE DIM. IF INTERNALLY INSULATED DUCT, DUCT LINER THICKNES = _______ IF INTERNALLY INSULATED DUCT, DUCT LINER THICKNES = _______ AIR FLOW DIRECTION AIR FLOW DIRECTION "R" = LEFT TO RIGHT UP "L" = RIGHT TO LEFT DOWN SPECIAL INSTRUCTIONS ______________________________ ____________________________________________________ ____________________________________________________ "R" = LEFT TO RIGHT UP "L" = RIGHT TO LEF T DONW SPECIAL INSTRUCTIONS ______________________________ ____________________________________________________ ____________________________________________________ _______ KW @ ________ VOLTS ____ PHASE = ______ _______ KW @ ________ VOLTS ____ PHASE = ______ TOT.AMPS TOT.AMPS _____ (____KW) STEPS @ _____ AMPS PER STEP _____ (____KW) STEPS @ _____ AMPS PER STEP WATTS DENSITY = ____________ KW/FT2 WATTS DENSITY = ____________ KW/FT2 LIST HEATER BASE W _____ + H_____ = _____@ $_______ LIST HEATER BASE W _____ + H_____ = _____@ $_______ MODEL ADDRESS MODEL ADDRESS KEY NO. KEY NO. _____________ ___________ = _______ _____________ ___________ = _______ _____________ ___________ = _______ _____________ ___________ = _______ _____________ ___________ = _______ _____________ ___________ = _______ _____________ ___________ = _______ _____________ ___________ = _______ CONTROL OPTION KEY NO. 72-____ 73-____ 76-____ 78-____ QTY ( ) ( ) ( ) ( ) ________ ( ) ______________________ _______ = _________ ________ ________ ( ( ) ______________________ ) ______________________ _______ = _________ _______ = _________ ________ ________ ________ ( ( ( ) ______________________ ) ______________________ ) ______________________ _______ = _________ _______ = _________ _______ = _________ DESCRIPTION PRODUCT OF AIR FLOW__ LIST EACH $______ = ________ CONTROL CHARACTORS_ $______ = ________ CONTROL TRANSFORMER $______ = ________ BRANCH CIRCUIT FUSING $______ = ________ LESS __________ % HEATER LIST PRICE EA. $_______ X COST MULTIPLIER ________ HEATER NET PRICE EA. $______ CONTROL OPTION KEY NO. 72-____ 73-____ 76-____ 78-____ QTY ( ) ( ) ( ) ( ) ________ ( ) ______________________ _______ = _________ ________ ________ ________ ( ( ( ) ______________________ ) ______________________ ) ______________________ _______ = _________ _______ = _________ _______ = _________ ________ ________ ( ( ) ______________________ ) ______________________ _______ = _________ _______ = _________ DESCRIPTION PRODUCT OF AIR FLOW__ $______ = ________ CONTROL CHARACTORS_ $______ = ________ CONTROL TRANSFORMER $______ = ________ BRANCH CIRCUIT FUSING LESS __________ % 33 LIST EACH $______ = ________ HEATER LIST PRICE EA. $_______ X COST MULTIPLIER ________ HEATER NET PRICE EA. $______ Page 32 INDUCTO DUCT HEATER SUGGESTED SPECIFICATIONS 2. Ceramic coil supports to be floating, but contained, and easily replaceable. 3. Ceramic coil insulators to be on staggered spacing per rack to eliminate blank areas in the air pattern thru the heater, and provide uniform heating over the entire cross section of the element. 4. Racks to support element coils on no more than 3 ½ " centers. General 1. Provide Series "HF" Inducto, open coil, electric duct heaters, as manufactured by Markel Products Co. and as listed in the schedule. 2. Power voltage and phase, control voltage, wattage, duct size, number of steps to be as per schedule. 3. Heaters to be either Slip-in or Flanged type as called for. 4. Three phase heaters shall have balanced three phase steps unless specified otherwise. 5. All heaters to be UL listed for zero clearance to combustible surfaces and bear the UL label. 6. All heaters shall meet the requirements of the latest National Electric Code. 7. Standard terminal box, recessed terminal box, standard control cabinet, remote control cabinet as well as element housing and racks all to be made of heavy gauge galvanized steel. (Aluminized steel optional.) 8. All heating coils to be made of high grade nickle/chromium resistance wire and terminated by means of a loop of wire being sandwiched between stainless steel or nickle plated washers and terminal hardware. All terminal hardware to be insulated from the heater by a two piece ceramic bushing. Terminal Box or Control Cabinet 1. Shall be constructed of heavy gauge galvanized steel (aluminized optional) and in sizes up to 18" x 18" shall be No. 20 gauge and over to be No. 18 gauge. All boxes to have a solid cover, of the same gauge, complete with a piano type hinge on the longest side, approved tool operated latch and pull ring. Covers over 48" long to be provided with two latches and pull rings. 2. Insulation consisting of ½ " high density fiberglass will be provided, attached to the cabinet, between the cabinet and the heating section. 3. Recessed terminal boxes used when ducts are internally insulated, or in air handling units, to be of the same general construction as item 1 above. Airflow Direction Heaters will be interchangeable for mounting in a horizontal or vertical duct except when position sensitive mercury contactors, SCR's or capillary type limit controls are built-in. In these cases, airflow direction must be specified. Element Assembly 1. To be of "Modular" design with each module independently and easily removable from the terminal box or control cabinet. 2. Each module to contain no more than 2 layers of element coils so that any one coil may be replaced without disturbing others. 3. Element coils of each module to be on staggered spacing so that all coils per module will be in the air stream, and shadowing (overheating) and/or blank areas eliminated. Safety Controls 1. Primary over temperature protection shall be provided by built in disc type automatic reset thermal cutouts for duct heaters up to 10' in width. Heaters over 40" high require two cutouts. Capillary type automatic reset thermal cutouts are required for any heater 10' wide or over. Capillary type controls to be UL listed and of the "fail safe" type. 2. Secondary over temperature protection shall consist of a sufficient number of load carrying replaceable disc controls to de-energize the elements if the primary system fails. Alternate A — One pilot duty manual reset and back up contactors. B — Replaceable heat limiters for single phase heaters. C — Bottom insert type heaters require a capillary type manual reset and back up contactors. Capillary type manual resettable cutouts are required for all heaters 10' wide or over, recommended to be used on all heaters over 6' wide, and must be of the "fail safe" and "trip free" type. Element Housing 1. To be of No. 18 Ga. galvanized (aluminized) steel and to be of roll-formed construction with multiple brakes and ribs for stiffness and rigidity. 2. Each housing module to be no more than 4¾ "wide (in direction of air flow) and contain 2 layers of element coils on staggered spacing. (2 mod. = 9 1/8") Element Rack 1. To be constructed of No. 20 Ga. galvanized (aluminized) steel and formed with multiple brakes and ribs for stiffness and rigidity. Maximum individual rack length to be 30". 34 SUGGESTED SPECIFICATIONS (CONT’D) 4, All manual safety devices shall be servicable thru the terminal box without removing the heater from the duct. 3. Overcurrent protection incorporating fuses or circuit breakers must be provided for all heaters rated more than 48 amperes, factory installed, within the heater enclosure, or provided as a separate assembly by the heater manufacturer. Heaters exceeding 48 amperes total line current must be divided into subcircuits (as allowed by stages) of less than 48 amperes and be protected at not more than 60 amperes. The main conductors supplying these overcurrent protective devices are considered branch circuit conductors and are subject to the 125% ampere rating rule of NEC. Wiring Diagrams 1. A separate, complete and specific wiring diagram shall be permanently attached to each heater. Typical wiring diagrams are not acceptable. 2. Control and line terminals in each heater shall be marked identical to the wiring diagram. 3. Additional diagrams, instructions, etc., to be firmly held in position by a metallic snap clip or pocket inside the cover. Available Built-in Components 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Disc type automatic high temperature cutouts. De-energizing break magnetic contactors. Replaceable Thermal Cutoff (disc type). Load carrying manual reset high temperature cutouts, disc type, and backup contactor. Non-fused disconnect switches. Class H, one time fuses 125% rated per the NEC except: a. line fusing for a bottom insert type construction must be in a separate remote box.. b. Circuits in a remote box cannot be group fused, each circuit must be fused separately. SCR Controls. Load carrying P.E. switches. Transformer with fusing per UL requirements. Electric or pneumatic step controllers. Differential pressure switch fan interlock. Time delay between stages. Indicator pilot lights, first stage on. 14. Pilot switches. 15. Cover interlock switch, pilot duty. 16. Pilot relays. 1 7 . Capillary type automatic high temperature cutouts. 18. Disconnecting break magnetic contactors. 19. Mercury contactors -de-energizing, disconnecting. 20. Capillary type manual reset high temperature cutouts. 21. Manual reset high temperature cutouts pilot duty and back-up contactors. 22. Fused disconnect switches. 23. Circuit breakers. 24. Dual element fuses. 25. Transfomer: class II integrally protected, secondary fused. 26. Electrical fan interlock. 27. Indicator pilot lights, each stage on, panel energized, etc. Other Optional Features 1. 2. 3. 4 . Dustproof terminal box, control cabinet. 5 . Remote control cabinet, standard, dustproof. 6. Bottom insert construction. 7 . Dual terminal box construction, flanged, insert. 8. Terminal box overhang on, downstream side, top, bottom. Aluminized terminal box, control cabinet, heater element assembly. For stainless steel construction consult factory. Protective screens, inlet side, outlet side, both sides. Flanged heater frame for plain ducts or internally insulated ducts. 35