Electro Industries ELECTRO DUCT User manual

12/20/2017 EI505

INSTALLATION MANUAL, PLENUM

Size

C=Plenum

EM-DI ** *5 * 16W x 16D

kW Stages

10 = 9.6 kW 2 = 2

15 = 14.4 kW 3 = 3

20 = 19.2 kW

INTENDED USE – This product is approved and label certified for water source heat pumps or

air handlers at the blower discharge, upflow only.

Drawings: EH503

ES501

XX017

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APPLICATION

This model series contains the starter plenum, its primary application is Econar manufactured

water source heat pumps. However, it can easily be adapted to other manufacturers

(ClimateMaster, etc.) having a 16 x 16 starting collar.

Electro Industries also has insert models (without starter plenum) primarily intended for

Command-Aire or other water source heat pump brands. Contact factory for assistance.

For information, all units are rated at 24Ø volts AC. When operating at lower source voltage,

the output may be reduced.

Example: 9.6KW unit, assuming normal element tolerances

220 volt source - 8KW

208 volt source - 7.3KW

NOTE: The maximum inlet air temperature is 100° F. For inlet temperatures greater than

100°, contact the factory for special assistance.

NOTICE TO HOMEOWNER AND INSTALLER

Hi-limit cycling two to ten minutes after initial turn on usually means improper deflector, baffle

installation, or insufficient airflow - carefully study and follow mechanical installations.

INSTALLATION REQUIREMENTS

1. All installation work must be performed by trained, qualified contractors or technicians.

Electro Industries, Inc., sponsors installation and service schools to assist the installer.

2. All electrical wiring must be in accordance with National Electric Code and local electric

codes, ordinances, and regulations.

3. Observe electric polarity and wiring colors. Failure to observe could cause electric shock

and/or damage to the equipment.

4. This unit can only be used for its intended design as described in this manual. Any internal

wiring changes, modifications to the circuit board, modifications or bypass of any controls, or

installation practices not according to the details of this manual will void the product

warranty, the ARL certification label, and manufacturer product liability. Electro Industries,

Inc., cannot be held responsible for field modifications, incorrect installation, and conditions

which may bypass or compromise the built-in safety features and controls.

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SPECIFICATIONS - TABLE 1

NOMINAL MIN. ELEMENT SOURCE INTERNAL SHIP

MODEL KW CURRENT+ CFM* CROSS SECTION CB FUSE WEIGHT

EM-DI1025C 9.6 40 1000 8 W x 16 D 50 N/A 15

EM-DI1535C 14.4 60 1500 8 W x 16 D 75 30 & 50 19

EM-DI2035C 19.2 80 2000 8 W x 16 D 100 50 & 50 21

* Assumes 100F inlet and all air passes through element rack. If duct/plenum is larger than element rack (without

factory deflector kit), the air volume external

(passing around) to the element rack must be added to this CFM requirement.

+ At 240 volt, single phase.

FUNCTIONAL DESCRIPTION

Refer to drawing ES5Ø1 and the symbol definitions.

Thermostat Connections - The following descriptions begin at the 24 volt control points. These

are the left lettered terminals on drawing ES5Ø1 shown as square dots.

C - Common, must be tied to 24 volt system common.

W1 - First stage heat, first 5KW section (10KW if "X" jumper is in place).

X - Second 5KW stage, factory jumpered to the "W1" terminal. Typically the "W1" function

controls the first 10KW. An outdoor stat (ODT) can be electrically installed in place of

the "X" to "W1" jumper to keep 5KW off during warmer outside temperatures.

W2 - Second stage heat, 5KW for 15KW model or 10KW for 20KW model.

O - Tie point only for wiring from room stat, no internal connection.

Y2 - Tie point only for wiring room stat compressor wire, basically no internal connection.

R - 24 volt high side, not required for normal functions, can be used as thermostat wire tie

point. Required if the room stat or air handler does not have internal blower "on"

function.

NOTE: This Electro-Duct blower turn on function cannot operate the air handler blower

relay without 24 volts at "R".

G - Air handler blower relay control voltage.

F - Room stat blower input wire, typically tied to room stat "G" terminal.

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Heater Turn-On Action - The external application of 24 volts AC between "W1" and "C"

pulls K2 relay which acts as a switch for the top 4.6KW element (E1). The red LED next to the

"W1" terminal illuminates. A signal is also diode coupled to K1 and yellow LED illuminates. K1

provides an electrical path between "R" and "G" to operate the air handler blower relay.

With external 24 volt AC between "X" and/or "W2", the same basic action follows switching on

elements E2 and E3. However, these two stages or elements contain an electronic delay of

approximately 10 seconds before K2 and/or K3 pull in. The LED opposite the appropriate terminal

indicates the control system has the appropriate element switch relay closed.

First Level Hi-Limit - The upper off-set hi-limit is connected to the two tab terminals shown on

diagram ES5Ø1 bottom left. If this limit opens due to low airflow, the top PC board red LED is

illuminated and K2, K3, and K4 relays open disconnecting all element power. This is an automatic

reset hi-limit which means it will again close (top LED off) re-establishing the element power. If this

is a cycling function, damage will result to the element relay contacts and/or elements themselves.

Second Level Hi-Limit - The hi-limits in the current carrying leg (between fuse and element) is a

dual function device. The automatic reset internal limit is set 50 below the fuse link internal

function. In other words, if the automatic reset contacts weld, the one time (permanent open circuit)

fuse link will prevent element overheating.

AUX 10 Pin Connector - For special OEM applications and for other plug-in optional devices, the

10 pin connector is represented by the various numbered terminals on the schematic diagram.

19.2KW Model - This is an added element to the 15KW shown. The fourth element has its

own relay tied directly across E3 element power. Whenever K4 switches on the E3 element, the

E4 follows immediately. The 30 amp fuse is changed to a 50 amp fuse.

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MECHANICAL INSTALLATION

The heat pump manufacturer's starter collar should be centered over the discharge blower.

Generally the blower shaft is 9Øto the facing front of this Electro-Duct. In other words, if you

would be viewing the blower motor shaft, you would see the side of the electrical control box.

Also blower centering means, the approximate 3 inch opening of the blower discharge is

centered under the electric elements. It does not mean the complete blower housing discharge is

centered, only the actual blower discharge opening itself.

In the case of the Econar unit, the Electro-Duct right side extended lip (facing Electro-Duct

control box), simply lapse on the right side of the Econar cabinet and the Electro-Duct center

side hole alignment with Econar cabinet center side screw.

ELECTRICAL HOOKUP

1. 240 VOLT SOURCE - Locate correct model number and KW size in Table 1 to determine

operating current and minimum source circuit breaker size. According to local codes,

building type, wiring run distance, etc., use the appropriate electric conductor size to

bring over the 240 volt source power. Connect to fuse block/input terminals (10KW is

terminal block only).

2. GROUNDING - Route and install the appropriate size ground conductor between the ground

lug labeled "GROUND" and building service entrance panel ground buss. This must be a

conductor sized according to the total amp rating of the appropriate model. Conduit is

not a adequate ground conductor.

3. THERMOSTAT CONTROL - See drawing EH5Ø3 and previous Functional Description

section for basic hookup:

A. Outdoor stat is not required, factory jumper is provided between "W1" and "X".

B. "W2" is not available on 10KW models.

C. 10KW model can be operated from a two stage room stat ("W1" and "X"). Remove

jumper between "W1" and "X", connect stat "W1" to "W1" and "W2" to "X".

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OPERATIONAL MONITOR LIGHTS

Green - 24 volt at "R", reference to "C".

Amber - Internal blower relay is pulled based upon an input

on either "W1", "X", or "W2".

Red (opposite stat terminal) - 24 volts (reference to "C") is at the terminal next to the red

light.

Top Red Light - First level hi-limit is open, overheat condition, insufficient airflow, dirty

filter, etc.

CFM CALCULATIONS

By measuring the temperature rise across this Electro-Duct (at a point high enough for proper

air mixing) the actual CFM can be quite easily determined. If you are having difficulties

sustaining hi-limit operation (clicking noise/top red LED) it may be a good idea to calculate the

CFM according to the formula shown at the top of the next page. To arrive at a stable outlet

temperature, you can turn off the source power and remove the smallest fuse. This will allow

you to verify or calculate the CFM without reaching the hi-limit cycling. The full amount of

elements are not required to use this formula. The accuracy of this formula will depend upon the

ability to measure the outlet air at a properly mixed and uniform spot and the accuracy of both

the clamp on amp meter (AC voltmeter).

CFM = volts x amps x 3.4

temp. rise x 1.1

REPLACEMENT PARTS

Part Number

- PC Module, 2 stage DI66Ø5

- PC Module, 3 stage DI66Ø6

- Element, 4.8KW EII# Ø6615

- First hi-limit, 135F EII# Ø5636

- Dual hi-limit EII# Ø663Ø

- Fuse - 5ØA EII# Ø664Ø

- Fuse - 3ØA EII# Ø5141

Page 1 of 2 XX017

Electro Industries, Inc.

Limited Product Warranty

Effective February 5, 2009

Electro Industries, Inc. warrants to the original owner, at the original installation site, for a period

of two (2) years from date of installation, that the product and product parts manufactured by

Electro Industries are free from manufacturing defects in materials and workmanship, when

used under normal conditions and when such product has not been modified or changed in any

manner after leaving the plant of Electro Industries. If any product or product parts

manufactured by Electro Industries are found to have manufacturing defects in materials or

workmanship, such will be repaired or replaced by Electro Industries. Electro Industries shall

have the opportunity to directly, or through its authorized representative, examine and inspect

the alleged defective product or product parts. Electro Industries may request that the materials

be returned to Electro Industries at the owner’s expense for factory inspection. The

determination as to whether product or product parts shall be repaired, or in the alternative

replaced, shall be made by Electro Industries or its authorized representative. Electro Industries

will cover reasonable labor costs to repair defective product or product parts for ninety (90) days

after installation.

TWENTY YEAR (20) LIMITED WARRANTY ON BOILER ELEMENTS AND VESSELS

Electro Industries, Inc. warrants that the boiler elements and vessels of its products are free

from defects in materials and workmanship through the twentieth year following date of

installation. If any boiler elements or vessels are found to have a manufacturing defect in

materials or workmanship, Electro Industries will replace them.

TWENTY YEAR (20) LIMITED WARRANTY ON SPIN FIN ELEMENTS

Electro Industries, Inc. warrants that the spin fin elements of its products are free from defects in

materials and workmanship through the twentieth year following date of installation. If any spin

fin elements are found to have a manufacturing defect in materials or workmanship, Electro

Industries will replace them.

FIVE YEAR (5) LIMITED WARRANTY ON OPEN WIRE ELEMENTS

Electro Industries, Inc. warrants that the open wire elements of its products are free from

defects in materials and workmanship through the fifth year following date of installation. If any

open wire elements are found to have a manufacturing defect in materials or workmanship,

Electro Industries will replace them.

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