HX18 18kW Heater
Read all instructions before using the heater Contents 1) Components... 3 Total Assembly... 3 2) Specifications... 4 3) Receiving... 4 4) Safety... 5 a) Grounding Block... 6 b) Power connections... 6 d) Air intakes and exhaust ports... 6 e) Exhaust temperature... 7 f) Connecting and disconnecting... 7 5) Operation... 8 a) Pre-startup... 8 b) Startup and Operation... 8 d) Shutdown... 9 6) Troubleshooting... 10 7) Replacing Fuses... 11 8) Replacing Resistors... 11 9) Preventative Maintenance of the Heater... 12 10) Service Parts... 13 2
IMPORTANT INSTRUCTIONS Lifting Handles 1) Components Customer Cable Inlet Switch Panel Air Intake Figure 1a Hot Air Exhaust Figure 1b Digital Thermostat Main Power Switch Step Switches Figure 1c Total Assembly Ready Light HX18 3
2) Specifications Blower Control power Rating 240VAC, single phase, 60Hz powered internally 240VAC, single phase, 60 Hz Continuous duty Power factor 1.0 Load elements The current at each step is subject to a manufacturing tolerance of ±5%. Enclosure Environmental Unit Weight Electro-statically powder coat, Blue: PPG PCTZ50108 Touch up paint is Pantone 280-c color. Plastikote custom color universal blend. Air inlet and outlet are covered by metal screens. Heat is discharged horizontally. 240V, 850CFM fan to bring outside air into the heater. 26 lbs. Dimensions 16.1 X 18.6 X 10.5 Step 1 2 3 Voltage (VAC) 240 240 240 Total Current (Amps) 14.43 14.43 14.43 43.3 Power (kw) 6.0 6.0 6.0 18.0 Table 1 3) Receiving WARNING! ELECTRIC SHOCK HAZARD. Electric shock can lead to severe injury or death. If the heater has been damaged in transit, do not operate until a competent technician inspects the unit and determines that it can be operated safely. 1) Check the equipment for obvious damage. 2) Document and report any exterior damage to the carrier immediately. 4
4) Safety This heater is designed for a variety of loads. Because of this, it is possible that voltages higher that those applied can be present inside the heater and at external connections of the heater. Work on the heater s internal systems should only be attempted by highly trained technicians and only when power has been disconnected and cannot be reconnected to the unit. IMPORTANT INSTRUCTIONS When using electrical appliances, basic precautions should always be followed to reduce the risk of fire, electrical shock, and injury to persons, including the following: 1) Read all instructions before using this heater. 2) This heater is hot when in use. To avoid burns, do not let bare skin touch hot surfaces. Use handles when moving this heater. Keep combustible materials, such as furniture, pillows, bedding, papers, clothes, and curtains at least 8 feet (1.8 meters) from the exhaust of the heater and keep them away from the sides and rear. 3) Extreme caution is necessary when any heater is used by or near children or invalids and whenever the heater is left operating and unattended. 4) Remove all animals and plants from area to be heated 5) Always unplug heater when not in use. 6) Do not operate any heater with a damaged cord or plug or after the heater malfunctions or has been dropped or damaged in any manner. Discard heater or return to authorized service facility for examination and/or repair. 7) Do not use outdoors. 8) Do not use in wet or moist locations 9) This heater is not intended for use in wet indoor environments. 10) Do not run cords under carpeting. Do not cover cords with throw rugs, runners, or similar coverings. Do not route cords under furniture or appliances. Arrange cords away from traffic areas and where it will not be tripped over. 11) To disconnect heater, turn controls off, then remove plugs from outlets. 12) Do not insert or allow foreign objects to enter any ventilation or exhaust opening as this may cause an electric shock or fire, or damage the heater. 13) To prevent a possible fire, do not block air intakes or exhaust in any manner. Do not use on soft surfaces, like a bed, where openings may become blocked. 14) A heater has hot and arcing or sparking parts inside. Do not use it in areas where gasoline, paint, or flammable liquids are used or stored. 5
15) Use this heater only as described in this manual. Any other use not recommended by the manufacturer may cause fire, electric shock, or injury to persons. 16) Always plug heater directly into a wall outlet/receptacle. Never use with a re-locatable power tap (outlet/power strip). 17) This heater includes a visual alarm to warn that parts of the heater are getting excessively hot. If the alarm light goes on, immediately turn the heater off and inspect for any objects on or adjacent to the heater that may cause high temperatures. DO NOT OPERATE THE HEATER WITH THE ALARM LIGHT ON. 18) SAVE THESE INSTRUCTIONS. a) Grounding Block WARNING! ELECTRIC SHOCK HAZARD. The ground terminal block must be connected to earth ground. Operating without a grounding connection could lead to injury or death. When the heater is in operation the ground block must be firmly and electrically connected to earth ground. Failure to do so could allow deadly voltage to be present on the surface of the enclosure. The grounding connection provides a low resistance path to ground b) Power connections WARNING! ELECTRIC SHOCK HAZARD. All power connections must be connected or guarded. Failure to do so will expose operators to possible shock and the possibility of grounding-out or shorting-out of the test power source. c) Control Power Use three phase distribution block connection from 240V customer source. d) Air intakes and exhaust ports Caution! All air intakes and exhaust ports must be clear and fully open. High volumes of cooling air are needed to prevent load elements from overheating. By their very nature, resistors under load convert electrical energy to heat. This heat must be removed from the unit. The blower, intake, and exhaust ports are sized to provide the proper amount of cooling air. Preventing or limiting air flow will allow the heater to overheat. 6
To increase the life of the load elements, allow the fan to run at least three minutes after the load is removed or until exhaust air is cool. No ductwork is permitted on intake or exhaust of this heater as this will cause a backpressure and ruin the resistors. Caution! Material can be moved by intake air or exhaust air. Failure to secure material could cause injury to bystanders or damage to the heater. Good air flow keeps the heater cool but can very easily move light debris such as paper, cardboard, and dust with great velocity. Loose materials around the heater, especially near the intake and exhaust, must be secured to prevent movement. Material on the exhaust side may be blown into and injure a bystander. Material near the intake may be taken into the heater damaging internal components. e) Exhaust temperature WARNING! FIRE AND BURN HAZARD. Keep flammable material at least 40 feet away from the heater. A great deal of heat is expelled from the heater. Temperatures inside the heater are sufficient to ignite flammable fumes or materials. Failure to maintain proper housekeeping and properly securing flammable material could lead to fire, burns, and/or injury. Even with sufficient air flow, internal component temperature will exceed 400 F. Exhaust air temperature rise of 100 F can be achieved at full power. Flammable materials must not be kept around the heater. Heat from the heater could ignite this material. f) Connecting and disconnecting WARNING! BURN HAZARD. Attempting to connect or disconnect leads while heater is in operation can lead to severe injury or death. Connecting or disconnecting plugs and receptacles while current is flowing or voltage is present may cause arcing. Arcing can generate a great deal of light, heat and possibility of electrocution. 7
5) Operation a) Pre-startup 1. Check housekeeping in the operational area and correct all unsafe conditions. Failure to do this may result in debris being blown around and may cause a fire hazard. 2. Connect the heater s ground block to a known earth ground. 3. Position heater so that air will flow freely into the intakes and out of the exhaust port. 4. All air intakes and exhaust ports must be clear of any blockages or debris. 5. For best results it is recommended that all doors, window, vents, and air conditioners in the heating area be insulated Plate b) Startup and Operation 1. Connect the 3-phase 240VAC power source to terminal blocks. Begin by removing the plate on the top of the heater using #2 Philip s head screw driver. Then, connect three phase power and ground to the terminal blocks. (See Figure 2) 2. Ensure all cable sizes are sufficient to carry the expected current. Failure to size conductors properly will lead to conductor overheating, which will damage conductors and may pose a fire hazard. 3. Put the Main Power switch in the ON position. The fans should now engage, and the digital thermostat should turn on. 4. To adjust the desired room temperature, put load switches in the ON position as desired to engage the resistors. Press the SET button on the thermostat, then use the UP/DOWN arrows to change the value displayed on the digital thermostat to the desired temperature Terminal Blocks Figure 2. Powering the Controls 8
SET Button Temperature Controls Temperature Display Figure 3. Thermostat 5. The heater will now generate heat until the temperature at the thermostat reaches the desired temperature. The heater will automatically turn the heater elements on and off as required to control to the desired temperature being sensed at the thermocouple(s). 6. Note that your heater thermostat is programmed with a 2 F hysteresis value. d) Shutdown 1. Put all step switches in the OFF position and lower thermostat value to below standard room temperature. 2. Allow fan to operate at least three minutes or until exhaust air is cool before shutting them off. This cooling period will extend the life of your heater. 3. Put the Main Power switch in the OFF position. 4. Turn off source power and customer is to confirm prior to disconnection of power cables from terminal blocks. 5. Remove grounding connections. 6. Move the unit to storage. 9
6) Troubleshooting Thermostat/Heater Will Not Turn On Blower will not turn on. Load steps will not turn on. Over temperature light. Make sure the source power is on. Ensure proper power connections. Ensure Main Power switch is in the ON position. Check for debris preventing fan from turning. Check control fuse (FS1). See Figure 4. Check over temperature sensors (OTS). See Figure 4. Check control fuse (FS1). See Figure 4. Check resistor continuity. See schematic. Check resistor step fuses. See Figure 4. Check the temperature set point (SP). This is an indication that the internal cabinet temperature has exceeded 150 F. Make sure the cabinet is ventilated. Check over temperature sensors (OTS). See Figure 4 Control OTS Control Fuse (FS1) Step Fuses Resistor OTS (on the underside of the middle resistor) Figure 4. Thermal Switch and Fuses 10
7) Replacing Fuses Using a #2 Phillips head screwdriver, remove the 16 screws from the cover panel. Carefully remove the panel from the unit. Service on fuses can then be performed. #10-24 Truss Head Screw Figure 5. Replacing Fuses 8) Replacing Resistors Consult Mosebach Manufacturing Co. 11
9) Preventative Maintenance of the Heater 1. Do not use a power washer to clean off the exterior of the unit. It is high voltage electrical equipment. Component Action Frequency Entire Unit All exterior bolts that hold the sheet metal. Resistance readings Electrical Components/ Wiring Fan Contactors Walk around the heater and inspect for : a) Obvious Damage b) Loose hardware Tighten the 10-24 hardware to 21 in.-lbs. Using an ohm meter, check each step for the correct resistance. The resistors should have continuity between input and output. These values are part of Appendix B wiring schematic. Check throughout the unit for loose wires, or electrical components that are no longer secure to their mounting plate. Check the fan for damage that could cause the airflow to change such as damaged or missing bearing, or damaged blades. Ensure contacts are opening and closing Check every use Check monthly. Check every 6 months Check every 6 months Check Annually Check Annually 12
10) Service Parts Description Fan Resistor Elements Fuses Temperature Controller Thermistor Contactors Part Number BLWR-0055-0068 RA-0055-0312-1 RA-0055-0312-2 RA-0055-0312-3 5A = AGC-5 60A = EC-9500-0739 EC-9500-1877 EC-9500-1871 EC-9500-1944 2 1 0 Initial Release DMK 9/28/16 Rev. Description Rev. By Date Copyright 2016 Mosebach Manufacturing Company MOSEBACH MANUFACTURING COMPANY 1417 McLaughlin Run Road Pittsburgh, PA 15241-3103 USA T: 412.220.0237 Customer Care OM-HX18.doc September 28, 2016 SAVE THESE INSTRUCTIONS F: 412-220-0236 www.mosebachresistors.com 13