Modine Manufacturing HEX5 Series Quick start guide

WARNING! Read all important information notices on pages 3–5

ISO 9001

2-519.6

5H723536A

Part No. 11520.Rev.2.00 Issued June 2017 Printed in Canada

HEX5 Series

Installation, Parts, Service, and Maintenance Manual

approved Locations

The Electric Forced Air Heaters are cULus listed certified for the following locations:

Class I, Divisions 1 & 2, Groups C & D; Class II, Division 1, Groups E, F & G; Class II,

Division 2, Groups F & G; Class I, Zones 1 & 2, Groups IIA & IIB; Temperature Code

T3B 329˚F (165˚C)

For details of hazardous locations with potential for explosion, refer to the Canadian

Electrical Code, Part 1, Section 18 or National Electrical Code articles 500–516.

C US

Listed

FX5 ‑ 480 3 60 ‑ 350 ‑ W ‑ T

Model

Series

5th Generation

Heater Voltage

208V, 240V,

480V, 600V

Phase

1, 3

Hertz

50, 60

Heater Kilowatts

Welded Core

T – XT-311 Thermostat with slim

junction box

XT-411 Thermostat with large

junction box

D – Built-in disconnect

P – Built-in pilot light

S – 3-way switch

Model Coding

H – Unit with high “off” de-energized

ambient temperatures

C – Heresite®coating

A – Stainless steel cabinet

U – Continuous fan

B – Low ambient option -50°F (-50°C)

L – Large junction box

HEX5

60 Hz Models only

TABLE OF CONTENTS

A. Heater Maintenance Checklist 3

A.1 Preventative Maintenance Grid .............................................................................3

A.2 Periodic................................................................................................................4

A.3 Annual..................................................................................................................4

B. Important Notices 5

C. Troubleshooting Tips 6

D. Installation 7

D.1 Mechanical ...........................................................................................................7

D.2 Electrical ..............................................................................................................9

D.3 Wiring Schematics ............................................................................................. 11

E. HEX5 Technical Data 12

E.1 60 Hz Electric Heaters ........................................................................................12

F. Specifications 14

F.1 60 Hz Models......................................................................................................14

G. Parts Assembly Diagram 16

H. Parts List 17

I. Repair & Replacement 18

A. HEATER MAINTENANCE CHECKLIST

Heater Model

Serial Number

Comments

Date of Maintenance

Maintenance Done By

WARNING

Disconnect heater from power supply at integral disconnect or fuse

box before opening enclosures or servicing heater.

IF INTEGRAL DISCONNECT IS BEING SERVICED, verify that

power has been disconnected at fuse box or main panel.

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

switch to prevent unexpected power application.

This heater should only be serviced by personnel with heating

and hazardous location equipment experience.

A.1 Preventative Maintenance Grid

Cells of the grid with check boxes inside are the minimum maintenance measures required to be performed at the

indicated time periods.

Regular Service Severe Service

To-Do Description Annual

Start Up Monthly Every 3

Months

Every 6

Months

Annual

Start Up Monthly Every 3

Months

Every 6

Months

Clean

Remove dust using compressed air. Do not spray with water

or solvents. Do not immerse in water or solvents. Clean the

following:

1. Motor

2. Louvers

3. Finned Tubes

4. Fan

5. Fan Guard

Check

1. Motor for smooth, quiet operation

2. Louvers for proper angle and tightness

3. All explosion-proof covers for tightness

4. Pressure relief device for signs of leakage. See Figure 1,

page 5 and refer to A.3 Annual, page 4 for further

instructions.

Electrical

Inspection

1. Inspect all terminal connections and conductors:*

Tighten loose connections. Replace conductors with

damaged insulation and frayed wiring.*

2. Inspect contactor contacts: If badly pitted, burned or

welded shut, replace with factory supplied contactor.*

3. Check fuses: The correct fuse rating and type are printed

on the circuit board. Always ensure a backup fuse is

available on the PCB.*

Mechanical

Inspection

1. Fluid leakage: Inspect the Pressure Release Valve (PRV)

label indicator for signs of rupture and degradation. If any

fluid leakage occurs from the heater, disconnect it from the

power supply and replace the core immediately.*

2. Enclosures: The interiors of each enclosure must be clean,

dry, and free of foreign materials.*

3. Motor shaft bearing and play: If the motor does not run

quietly and smoothly and has excessive play, replace the

motor.*

*For drilling rigs, this should be done every rig re-location.

Photocopy

this page

for reuse.

Heater Maintenance Checklist

Photocopy

this page

for reuse.

A.2 Periodic

• Clean

Motor

Louvers

Finned Tubes

Fan

Fan Guard

• Check

Motor for smooth, quiet operation

Louvers for proper angle and tightness

All explosion-proof covers for tightness

Pressure relief device for signs of leakage.

See Figure 1, page 5 and refer to Annual,

page 4 (Fluid leakage), for further instructions.

A.3 Annual

• Mechanical Check

Fluid leakage. The heater core is vacuum charged

and contains propylene glycol. Inspect the

Pressure Relief Valve label indicator for signs

of rupture and degradation. If the paper is torn,

disintegrated or otherwise compromised this

is an indication that fluid has leaked from the

core. If any fluid leakage occurs from the heater,

disconnect it from the power supply and have the

core replaced. A factory supplied exchange core

can be shipped immediately from stock. Refer to

Section Repair & Replacement, page 18 for

details.

All enclosures. Interior of enclosures must be

clean, dry and free of foreign materials. Threaded

covers must be installed and hand tight.

Note: Enclosure joints are metal to metal. Do

not use gasket material or sealant in joints.

A grease is applied to the joints at the

factory and should be left intact.

Motor shaft bearing play. Replace motor if play

is excessive, or if motor does not run quietly

and smoothly. Motor bearings are permanently

lubricated.

Fan. Replace immediately if cracked or damaged.

Louvers. Screws should be tight. Louvers shall

not be fully closed or override stops.

Tightness of all hardware. All nuts and bolts,

including mounting hardware, must be tight.

Turn heater on for a minimum of five minutes.

Check for warm air exiting heater through louvers.

Crackling or pinging noises within heater during

start-up are normal.

• Electrical Check

All terminal connections and conductors. Tighten loose

connections. Conductors with damaged insulation

must be replaced.

Inspect contactor contacts. If badly pitted, burned or

welded shut, replace with factory supplied contactor.

For severe duty conditions such as arctic duty or

drilling rigs, Modine recommends the contactor be

replaced every two years.

Fuses. Fuse rating and type are on printed circuit

board. Correct fuse must be in the active fuse clip. It is

recommended that a spare fuse be stored in the spare

fuse clip.

All explosion-proof conduits. Replace damaged

conduits. All threaded conduit connections must have

a minimum 5 turns engagement. Straight threaded

conduit must protrude a minimum of 1/16" (1.6 mm)

inside enclosures. Taper threaded connections must be

at least hand tight.

Electrical resistance on all load side legs. Reading

should be balanced (± 5%).

(before and as required during heating season)

(before heating season)

Heater Maintenance Checklist

B. IMPORTANT NOTICES

WARNING

Read and adhere to the following. Failure to do so may result

in severe or fatal injury. WARRANT Y WILL BE VOID.

1. Read and follow all instructions in this manual.

2. Heater is to be used only in atmospheres having an

ignition temperature higher than the heater’s maximum

rated operating temperature as shown on the heater data

plate. Refer to applicable electrical codes for additional

information.

3. Heater to be used only in the hazardous locations

indicated on the heater’s data plate.

4. Heater is for dry indoor use only. Do not immerse in water.

Do not store or use in areas exposed to rain or snow.

5. Heater is to be connected and serviced only by a

qualified electrician experienced with hazardous location

equipment.

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

applicable codes.

7. Disconnect heater from power supply at integral

disconnect or fuse box before opening enclosures or

servicing heater. IF INTEGRAL DISCONNECT IS BEING

SERVICED, verify that power has been disconnected

at fuse box or main panel. Lock the switch in the

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

unexpected power application.

8. This heater is equipped with a single bimetal

overtemperature high-limit. It is of the automatic reset type

and therefore the heater may restart without warning. The

heater is not to be operated with the high-limit disabled or

disconnected from the control circuit.

9. Venting pressure of the pressure relief valve (PRV) is

factory set. Do not tamper with lock nut. (See Figure 1,

page 5.)

10. Do not tamper or remove warning label indicator on

the PRV.

11. Operate the heater only while it is permanently mounted

in an upright position. Refer to Section D. Installation,

page 7 for details.

12. Heater must be kept clean. When operating in a dirty

environment, regularly clean the finned tubes, fan, and fan

guard. Follow the recommended maintenance procedures.

Refer to Section A. Heater Maintenance Checklist,

page 3 for details.

13. The heater core is vacuum charged and contains

propylene glycol. If any fluid leakage occurs from the

heater, disconnect it from the power supply and have

the core replaced with a factory supplied core. Refer to

Section I. Repair & Replacement, page 18 for details.

14. Do not operate the heater with any of the louvers fully

closed or overriding their stops.

15. Do not operate the heater in atmospheres corrosive to

steel or aluminum.

16. Do not operate heater in ambient temperatures above

104°F (40°C).

17. Use factory approved replacement parts only.

18. See applicable electrical codes for seal requirements in

field installed conduits. Factory installed conduits require

no further sealing.

19. Crackling or pinging noises within the heater core during

start up may occur. This is normal.

20. Air discharge near the bottom of the heater may be

warmer than the top. This is normal.

21. If there are any questions or concerns regarding the heater,

contact the factory. Refer to the back cover of this manual

for details.

PRV

PRV Lock Nut Pressure Relief Valve (PRV)

Label Indicator

PRV Body

Figure 1

Heater Maintenance Checklist

C. TROUBLESHOOTING TIPS

1. Heater is not operating.

1.1 Check all fuses in heater control box.

1.2 Check remote disconnect switch and circuit breaker.

1.3 Check voltage supplied to the heater – refer to the

heater data plate for voltage requirements.

1.4 Check thermostat by turning it and check continuity

with a multimeter.

1.5 Check the condition of the disconnect switch if the

heater is so equipped. Measure continuity through

the disconnect by engaging the switch.

1.6 Verify that there is a jumper wire present between

terminals 5 and 6 on the terminal block located in

the control box.

2. Contactor is chattering.

2.1 Check supply voltage.

2.2 Check wiring connections. Tighten all loose

electrical connections.

2.3 Check thermostat for continuity (See 1.4,

page 6). If thermostat does not break continuity

replace thermostat.

3. Contactor is burned or welded.

3.1 Check the contactor for burn marks and blackening.

Replace the contactor.

3.2 Check incoming power to the heater to ensure there

are no voltage fluctuations.

4. Heat exchanger is dirty.

4.1 Clean the heat exchanger using compressed air.

5. PRV has released.

5.1 If there are signs that the PRV has released fluid,

PRV indicator is broken, blackening around the PRV

exit hole, or there are fluid stains visible on the top

louver, shut the unit down immediately.

5.2 Check for restricted air flow, bad motor, broken

thermostat or malfunctioned high limit.

6. Heater is cold on top and warm on bottom.

6.1 The core may have lost its vacuum. Check the PRV

for signs of loss of fluid and verify that the PRV label

indicator is not broken. If PRV has released, send

the unit in for repair or replace the core.

6.2 If the PRV does not indicate loss of fluid, the heater

should operate normally.

6.3 The ambient temperature may be too low. If the

ambient temperature is very cold the top of the core

will be colder than the bottom – this is normal.

7. Unit cycles on high limit – unit turns on and turns off within

less than 5 minutes.

7.1 Check and see if the PRV has released fluid. Core

may have lost most or all of its fluid. If PRV has

released, send the unit in for repair or replace core.

7. 2 The core may be dirty, fan may not be working or

may be turning the wrong way (the fan must rotate

clockwise as seen from the front of the unit) objects

may be stuck in the heat exchanger for drying or

warming up – remove any items from the exchanger.

8. The Ground Fault Interrupter (GFI) trips on the main panel,

or heater blows fuses.

8.1 Check that you have a fuse of the proper amperage

rating.

8.2 Check for loose or frayed wiring.

8.3 If condition is not observable, send heater in for repair.

8.4 Change sensitivity of GFI.

9. The fan is turning but very little air comes from the front of

the heater.

9.1 Check fan rotation and ensure that the fan turns

clockwise as seen from the front of the heater. Refer

to the Installation section below for more information.

9.2 Check motor winding resistance and verify that they

are balanced.

9.3 Check fan blade set screws to ensure fan blade is

not loose on the motor shaft.

Troubleshooting Tips

D. INSTALLATION

All applicable codes must be adhered to. For optimum heating, the

heater should be installed as follows:

D.1 Mechanical

1. Location

1.1 There are no obstructions that may impede the

heater’s air inlet or discharge.

1.2 The air discharge is directed into open areas and not

at occupants.

1.3 The air discharge is not directed at a thermostat.

1.4 The air discharge is directed across areas of heat

loss, such as doors and windows (see Figure 2,

page 7).

1.5 The air discharge is directed along and at a

slight angle toward exterior walls (see Figure 2,

page 7).

1.6 If equipment freeze protection is important, direct air

discharge at equipment.

1.7 Air discharge streams support each other and

create a circular air flow. It is not required that the

heater’s air throw reaches the next heater (see

Figure 2, page 7).

Heater Locations

Exterior Wall

Figure 2

2. Mounting

2.1 The heater must be permanently mounted in a level,

upright position for operation. See Figure 3, Figure 4,

and Figure 5 on page 7 and 8 for maximum

tilt angles, installation clearances, and physical

dimensions. For ease of installation, a variety of

mounting kits are available from the factory.

2.2 The mounting structure must be strong enough to:

– Support the heater’s weight (refer to Section F.

Specifications, page 14).

– Provide sufficient stiffness to prevent excessive

vibration.

– Withstand harsh situations such as transportable

installations.

Maximum Tilt (Either Direction)

0.5"

(12.7 mm)

1.0"

(25.4 mm)

Figure 3

Minimum Installation Clearances

(Must be maintained for service and air flow)

30"

(762 mm)

Cabinet height plus 2" (51 mm)

for ease of core removal

(see below)

(102 mm)

72"

(1829 mm)

10"

, (254 mm)

For the maximum mounting height to

ensure warm air reaches the floor, refer to

Section F. Specifications, page 14

Obstruction

Figure 4

General Guideline for Installation and Wiring

Installation

Dimensional Tolerances +1/8" [+3 mm]

Unless otherwise specified.

Optional Built-in

disconnect switch

17 1/4" ±3/16"

[439 ±5 mm]

To field wiring opening

1" 1/2"

[38 mm]

max

3 7/8" ±1/4"

98.4mm ±6mm

3 9/16" ±1/8"

90.2mm ±3mm

1" NPT

(For field wiring on heaters

with integral disconnect)

22 5/8" MAX.

(575mm)

10 11/16" ±3/16"

(271 ±5mm)

3 3/4"

(95.3mm)

1 3/4" ±1/4"

(44 ±6mm)

8" ±1/4"

(203 ±6mm)

Ø5/8" (Ø15.5mm)

MOUNTING HOLES

(4 PLCS)

Optional Built-In

Disconnect Switch

17 1/4" ±3/16"

439mm ±5mm

To field wiring opening

1" NPT

(For remote room

thermostat, if applicable)

1 1/2" MAX.

(38mm)

Slim Junction Box

Optional Built-In

Thermostat

1" NPT

(For remote room

thermostat, if applicable)

9 1/4" ±1/4"

[235 ±6 mm]

1" NPT

(For field wiring on heaters

without integral disconnect)

3 9/16" +1/8"

[90.2 mm +3 mm]

3 7/8" ±1/4"

98.4mm ±6mm

3 9/16" ±1/8"

90.2mm ±3mm

1" NPT

(For field wiring on heaters

with integral disconnect)

22 5/8" MAX.

(575mm)

10 11/16" ±3/16"

(271 ±5mm)

3 3/4"

(95.3mm)

1 3/4" ±1/4"

(44 ±6mm)

8" ±1/4"

(203 ±6mm)

Ø5/8" (Ø15.5mm)

MOUNTING HOLES

(4 PLCS)

Optional Built-In

Disconnect Switch

17 1/4" ±3/16"

439mm ±5mm

To field wiring opening

1" NPT

(For remote room

thermostat, if applicable)

1 1/2" MAX.

(38mm)

Slim Junction Box

Optional Built-In

Thermostat

3 7/8" +1/4"

[98.4 mm +6 mm]

1" NPT

(For field wiring on heaters with

integral disconnect)

1" NPT

(For remote room

thermostat, if

applicable)

Optional Built-in

thermostat

ø5/8" [ø15.5 mm]

Mounting Hole

(4 plcs)

22 5/8"

(575 mm max.) 10 11/16"±3/16"

[271±5 mm]

8"±1/4"

[203±6 mm]

3" ±1/4"

[76 ±6 mm]

3 3/4" (95.3 mm)

3 7/8" ±1/4"

98.4mm ±6mm

3 9/16" ±1/8"

90.2mm ±3mm

1" NPT

(For field wiring on heaters

with integral disconnect)

22 5/8" MAX.

(575mm)

10 11/16" ±3/16"

(271 ±5mm)

3 3/4"

(95.3mm)

1 3/4" ±1/4"

(44 ±6mm)

8" ±1/4"

(203 ±6mm)

Ø5/8" (Ø15.5mm)

MOUNTING HOLES

(4 PLCS)

Optional Built-In

Disconnect Switch

17 1/4" ±3/16"

439mm ±5mm

To field wiring opening

1" NPT

(For remote room

thermostat, if applicable)

1 1/2" MAX.

(38mm)

Slim Junction Box

Optional Built-In

Thermostat

ø5/8" [ø15.5 mm]

Mounting Hole

(4 plcs)

22 5/8"

(575 mm max.)

10 11/16"±3/16"

[271±5 mm]

3 3/4" (95.3 mm)

1 3/4" ±1/4"

[44 ±6 mm]

8"±1/4"

[203±6 mm]

Slim Junction Box

Optional Built-in

thermostat

Figure 5

Installation

D.2 Electrical

WARNING

Disconnect heater from power supply at integral disconnect or

fuse box before opening enclosures or servicing heater.

IF INTEGRAL DISCONNECT IS BEING SERVICED, verify that

power has been disconnected at fuse box or main panel. Lock

the switch in the "OFF" (open) position and/or tag the switch to

prevent unexpected power application. Installation and wiring of

the heater must adhere to all application codes.

1. General

1.1 Use only copper conductors and approved

explosion-proof wiring methods during installation.

Refer to Section E. HEX5 Technical Data, page 12

to 13 and heater data plate for conductor rating.

1.2 External overcurrent protection is required. Refer

to Section E. HEX5 Technical Data, page 12

to 13 and heater data plate for voltage, frequency

amperage, and phase. Supply voltage is to be within

10% of the data plate voltage.

1.3 The heater must be installed by qualified personnel

in strict compliance with electrical codes.

1.4 All heaters come factory prewired and ready for direct

connection to the power supply leads.

1.5 The heater must be individually fused, preferably

with Class J time-delay fuses for maximum safety.

Unless stated otherwise in your local code, fuse size

shall be 125% of line current or next size larger.

2. Field Wiring

2.1 The supply conductors, ground conductor, and room

thermostat conductors (see D.3 Wiring Schematics,

page 11) all pass through the 1" NPT opening

(see Figure 6, page 9) and are to be wired into

the control enclosure (see Figure 7, page 9).

Rear View of Heater

Control enclosure

and cover

(Air exits through louvers)

1" NPT opening for field wiring Motor junction box

Air intake

Do not install conduit below heater. (See Figure 3)

Fan rotation

Figure 6

2.2 Heater may be supplied with a factory installed

built-in room thermostat (see Figure 8, page 10).

On heaters not supplied with this option, it is

recommended that a remote room thermostat

be used. Connect the remote room thermostat

conductors to the printed circuit board terminal

block marked “TSTAT”. Any thermostat used with

this heater must:

– Be of an explosion-proof type

– Be rated 125V minimum

– Have a minimum 2 amp capacity

– Open on temperature rise

2.3 Heater may be supplied with a factory installed built-in

integral disconnect. (See Figure 8, page 10)

Field Wiring for Integral Disconnect:

– Power Supply conductors and Ground

conductor pass through 1" NPT opening

of Disconnect Enclosure (see Figure 8,

page 10). Supply conductors to be wired to

Disconnect Switch inside. Ground conductor

to be wired to Ground Lug fastened to inside of

Disconnect Enclosure.

– If applicable, Remote Room Thermostat

conductors pass through 1" NPT opening (see

Figure 8, page 10) and are to be wired to

printed circuit board terminals marked “T’STAT”.

– To reduce risk of ignition of hazardous

atmospheres, conduit runs must have a sealing

fitting connected within 18" (457 mm).

2.4 Factory installed conduits require no further sealing.

Integral Disconnect is sealed at factory.

– The internal grounding terminal in the control

enclosure (or in the integral disconnect

enclosure when this option is provided) shall

be used as the equipment grounding means.

An external bonding terminal is provided for a

supplementary bonding connection where local

authorities permit or require such a connection.

Control Enclosure & Field Wiring

Connect supply conductors

to this side of contactor.

Contactor load

side terminals, this

side for factory

wiring only.

Active and

spare fuses

(see Section

H. Parts List,

page 17)

Printed circuit board

Figure 7

Installation

Optional Built‑in Disconnect & Field Wiring

Sealed at factory

1" NPT

(Remote room

thermostat if

applicable)

Terminals

marked

“T’STAT”

Load side

terminals

for factory

wiring only.

1" NPT

(Power supply)

Connect supply

conductors to this

side of switch

Switch

terminals

Figure 8

Optional factory installed

built-in disconnect.

Optional factory installed built-in

room thermostat.

Figure 9

3. Final Inspection

3.1 Before application of electrical power:

– Check that all connections are secured and

comply with the applicable wiring diagram

(see Wiring Schematics, page 11) and code

requirements.

– Confirm that the power supply is compatible with

the data plate rating of the heater.

– Remove any foreign objects from the heater.

– Install all covers and verify that all enclosures are

well secured.

– Ensure that the fan rotates freely. See Figure 6,

page 9 for proper direction of fan rotation.

Installation

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