Ruffneck RGE Series Regular Duty Forced Air Unit Heaters User Manual

Ruffneck RGE Series Regular Duty Forced Air Unit Heaters

IMPORTANT INSTRUCTIONS

Read all instructions before installing or using the heater. Please adhere to instructions published in this manual. Failure to do so may be dangerous and may void certain provisions of your warranty.

Model Coding

IMPORTANT NOTICES

CAUTION. This symbol indicates a potentially hazardous situation, which, if not avoided, may result in personal injury or damage to the equipment.

WARNING. This symbol indicates an imminently hazardous situation, which, if not avoided, can result in serious injury or damage to the equipment.

WARNING. Read and adhere to the following. Failure to do so may result in a risk of fire, electrical shock, and severe or fatal injury. The warranty will be void.

1. Read and follow all instructions in this manual.

2. This heater is intended to be used for commercial and industrial indoor space heating applications.
   WARNING. Heater is not to be used in hazardous atmospheres where flammable vapors, gases, liquids or other combustible atmospheres are present.

3. Heater is to be connected and serviced only by a qualified electrician.

4. Installation and wiring of the heater must adhere to all applicable codes.

5. Disconnect heater from power supply at disconnect or fuse box before opening enclosures or servicing heater. IF DISCONNECT IS BEING SERVICED, verify power has been disconnected at fuse box or main panel. Lock the switch in the “OFF” (open) position and tag the switch to prevent unexpected power application.

6. Do not operate heater in wet and humid environments.
   WARNING. Elements get hot during operation. Contact can cause burns.

7. Install and maintain clearances as per this manual.

8. Do not operate the heater in corrosive atmospheres.

9. Use factory replacement parts only.

10. Maximum ambient operating temperature is 40°C (104°F).

11. Do not operate the heater with the louvers deformed or damaged.

12. If there are any questions or concerns regarding the heater, please refer to contact information on the back page of this manual.

13. Follow the recommended maintenance procedures under Section I. Heater Maintenance Instructions, page 16.

INSTALLATION

All applicable codes must be adhered to. For optimum performance, the heater should be installed as follows:

Location

1. Ensure there are no obstructions that may impede the heater’s air inlet or discharge. Refer to Figure 1 and Figure 2, page 4, for minimum clearances.
2. Ensure the air discharge is not directed at a thermostat.
3. Ensure the air discharge is not directed towards areas of heat loss, such as windows.
4. Ensure the air discharge is directed along and at a slight angle toward exterior walls.
5. If equipment freeze protection is important, direct air discharge at equipment while maintaining minimum clearances.

Mounting

WARNING. Install heater with suffcient clearance to walls and ceiling as indicated in figure 2 on page 4. Mount with bottom of heater no less than 6 ft (1830 mm) above floor or grade.

1. The heater must be permanently mounted to a fixed location onto a wall or ceiling.

2. The mounting surface must be strong enough to:
   Support the heater’s weight.
   Provide sufficient stiffness to prevent excessive vibration.

3. The single bolt mounting is not designed for high dynamic loads that can occur during transportation. For heaters that are to be installed prior to transportation, it is recommended that temporary blocking or strapping be used to limit movement of the heater with respect to the mounting structure. Inspection of the mounting bolt for correct tensioning is also recommended after arrival at site to ensure no loosening has occurred in transportation. The mounting bolt/nut should be torqued to 65 – 75 ft‑lbs, refer to Table 5, page 11.

4. Install the bracket on the heater with hardware provided.

5. Orient the heater to its final position before tightening all hardware.

6. In higher vibration installations use of a removable thread locking compound such as Loctite® 243™ Blue Threadlocker is recommended.

7. Correct tensioning of the mounting bolt will include full compression of the split lock washer and inspection for correct thread engagement. The mounting bolt/nut should be torqued to 65 – 75 ft‑lbs, refer to Table 5, page 11.

8. The discharge air louvers are individually adjustable.

Table 1 – Heater & Bracket Dimensions

Table 2 – Installation Height & Heater Weight

Electrical

WARNING. Disconnect the heater from the power supply at the disconnect or fuse box before opening the enclosures or servicing the heater. Lock the switch in the “OFF” (open) position and tag the switch to prevent unexpected power applications. This heater should only be serviced by qualified personnel with electrical heating equipment experience. Install and use the heater in accordance with local codes and this manual.

1. General
2. Use only approved copper conductors for installation. Refer to Section G. Technical Data, page 12 and heater data plate for heater rating.
3. The power supply may be single or three phase as shown on the nameplate. Wiring diagrams are on the inside of the terminal compartment cover (or refer to B.3.7, page 5). Connection box volume: 2 to 10 kW: 9,893 cm³, 15 to 30 kW: 32,333 cm³.
4. Field Wiring Heater is supplied with an enclosure that has standard trade size conduit openings to accommodate the line conductors or external thermostat connection. Two 1/2″ or 3/4″ conduit knockouts are located on the 2 to 10 kW units. Two 1/2″, 3/4″, 1″ or 1-1/4″ conduit knockouts are located on the 15 to 30 kW units.
5. The heater may be supplied with a factory-installed built-in room thermostat. On heaters not supplied with this option, a remote thermostat is required. Connect the remote thermostat conductors to the terminal block, refer to Section 7. Sample Wiring Schematics – RGE Series Heater, page 5 – 7. Remote thermostats are available from the factory. Any thermostat used with this heater must be:
6. UL-listed or CSA approved
7. Rated for 240 volts minimum and 5 amps minimum.
8. Grounding: a copper compression terminal is located beside the terminal block. Ensure the unit is properly grounded before energizing.
9. Models without a built-in contactor should have the limit switch wired in the control circuit of an external contactor, and for a three-phase supply, this control circuit should be connected to L2 and L3 which feed the center heating element, refer to Figure 3E, page 7. The limit switch is rated 600 volts, 10 amps resistive.
10. Final Inspection Before application of electrical power:
11. Check that all connections are secured and comply with the applicable code requirements.
12. Confirm supply voltage is compatible with the data plate specifications.
13. Remove any foreign objects from the heater.
14. Ensure all external fittings and enclosure covers are secured.
15. Ensure fan rotates freely.
16. If equipped, ensure the manual reset thermal cut-out has been reset.
17. Sample Wiring Schematics – RGE Series Heater If the wiring schematics of Figures 3A – 3G, page 5 –7, do not match your configuration, check the inside access panel of the unit for a specific wiring schematic. Alternatively, all wiring schematics are available online at: www.thermon.com.

B.4 Sample Wiring Schematics RGE Series Heaters

• Figure 3A – RGE Series 2 – 10 kW wiring schematic with hi-limit option. 208 V and 240 V models.

B.4 Sample Wiring Schematics RGE Series Heaters (cont’d)

• If the wiring schematics of Figures 3A – 3G, page 5 – 7, do not match your configuration, check the inside access panel of the unit for specific wiring schematic.

• Figure 3B – RGE Series 2 – 10 kW wiring schematic with hi-limit and fused control circuit options. 208/240/480/600 V models.

• Figure 3C – RGE Series 2 – 10 kW wiring schematic with hi-limit, contactor, built-in thermostat, fan only switch options. 208 – 240V models.

• Figure 3D – RGE Series 2 – 10 kW wiring schematic with hi-limit, contactor, built-in thermostat, fan only switch, transformer and fused control circuit options. 208 – 600V models.
• B.4 Sample Wiring Schematics RGE Series Heaters (cont’d)

Figure 3E – RGE Series 15 – 30 kW wiring schematic with hi-limit option. 208 – 600V models.

• Figure 3F – RGE Series 15 – 30 kW wiring schematic with hi-limit and contactor options. 208 – 240V models.

• Figure 3G – RGE Series 15 – 30 kW wiring schematic with hi-limit, contactor, transformer and fused control circuit options. 208 – 600V models.

OPERATION

General

1. To operate heater, ensure power supply is properly connected as specified in the wiring schematic (refer to Figures 3A – 3G, page 5 –7).
2. If the heater is setup to operate on a thermostat, ensure the temperature set point is set high enough to turn on the heater
3. During normal operation, the thermal cut-out control should not cycle the heater ON and OFF. If cycling occurs, check to see if there is an airflow blockage. If there are no obstructions, the heater must be examined by qualified personnel to determine the cause of the thermal cut-out cycling.
4. Operate the unit for a minimum of 10 minutes to allow the heating elements to reach a steady state. If no warm air is discharged from the heater, shut off the unit and see Section F. Troubleshooting Tips, page 11.

REPAIR & REPLACEMENT

WARNING. Disconnect heater from power supply at disconnect or fuse box before opening enclosures or servicing heater.
Lock the switch in the “OFF” (open) position and tag the switch to prevent unexpected power application. This heater should only be serviced by qualified personnel with electrical heating equipment experience. Install and use the heater in accordance with local codes and this manual.

*Note:** ONLY USE FACTORY SUPPLIED REPLACEMENT PARTS OF THE SAME SPECIFICATION. REFER TO TABLE 3, PAGE 10 FOR COMPLETE LISTING OF AVAILABLE PARTS.

Heating Elements

1. Disconnect all wires connected to the heating element terminals. Remove louver assembly from heater. Remove heating elements, noting their proper placement.
2. Install factory-supplied replacement heating element (see Table 3, page 10 for Parts List).
3. Ensure heating element attaching screws are in good condition.
4. Re-attach heating element mounting screws and tighten.
5. Check heating elements are not in contact with the cabinet or each other.
6. Reinstall all wires with hardware provided. Torque the element terminal hardware to the torque specifications, refer to Table 4, page 11.
7. Reinstall the louvers.

Fan

1. Remove the rear grille. Remove the motor mount assembly. Remove the screw securing the fan to the fan hub attached to the motor.
2. Replace fan with factory-supplied fan. Install the fan such that the mounting hub collar of the fan faces the inside of the heater, i.e. facing towards the elements. Ensure motor shaft end is flush to hub collar.

Thermal Cut-Out

1. Disconnect all wires connected to thermal cut-out.
2. Remove two mounting screws.
3. Remove thermal cut-out switch from the enclosure.
4. Replace thermal cut-out with factory-supplied replacement thermal cut-out.
5. Reinstall thermal cut-out switch in the control enclosure.
6. Re-attach thermal cut-out mounting screws.
7. Reconnect all wires to thermal cut-out.

PARTS LIST

Description

1. Cabinet box assembly
2. Louver assembly
3. Motor mount
4. Motor
5. Fan blade
6. Cover panel
7. Rear grille
8. Non-finned (2–10 kW), Finned element (15–30 kW)
9. Thermostat – SPST
10. Thermostat knob
11. Transformer
12. Thermal cut-out
13. Terminal block, 6 pole
14. Terminal block, 3 pole
15. Contactor, 3 pole
16. Ground connector
17. Fuse

Table 3 – Parts List

*Note:* Not shown in Figure 5

TROUBLESHOOTING TIPS

Heater is not operating

1. Check all fuses.
2. Check the disconnect switch.
3. Check voltage supplied to the heater – refer to the heater data plate for voltage requirements.
4. Check the control voltage if the transformer is installed.
5. Check the thermostat by turning it and checking continuity.
6. Check the condition of the disconnect switch if the heater is so equipped. Measure continuity through the disconnect by engaging the switch.
7. Verify that there is a jumper wire present between the terminals as per the wiring schematics (refer to Figures 3A – 3F, page 5 – 7.
8. If the problem still exists, contact the factory.

Contactor is chattering

1. Check supply voltage.
2. Check the control voltage if the transformer is installed.
3. Check wiring connections. Tighten all loose electrical connections.
4. Check the thermostat for continuity. If the thermostat does not break continuity replace the thermostat.
5. Check for excessive heater vibration.
6. Do not operate if the problem persists. Contact factory.

Contactor is burned or welded

1. Check the contactor for burn marks and blackening. If present, replace the contactor.
2. Check incoming power to the heater to ensure there are no voltage fluctuations.
3. Check heating element for continuity.
4. Check the motor for continuity.
5. Check the thermostat for continuity. If the thermostat does not break continuity replace the thermostat.
6. Do not operate if the problem persists. Contact factory.

Heater cycles on high limit

1. Check the inlet and discharge louvers for air blockage.
2. Check for heating element fouling.
3. Ensure the motor is functioning and fan is rotating counterclockwise when viewed from the rear .
4. Do not operate if the problem persists. Contact factory.

Heater is operating but no heat is present

1. Check the control voltage to the contactor coil, if unit is equipped with a contactor and transformer. If the voltage is not within specification replace the transformer.
2. Measure and record all element resistances. Contact the factory to verify if the elements are within specifications. If not within specification replace heating element(s).
3. If the problem persists, contact the factory.

Heater fan does not operate but the heating elements operate

1. Ensure fan blade spins freely to check the motor bearings. Replace the motor as required.
2. Do not operate unit. Contact factory.

The Ground Fault Interrupter (GFI) trips on the main panel, or heater blows fuses

1. Check that you have a fuse of the proper amperage rating.
2. Check for loose or frayed wiring.
3. If condition is not observable, send the heater in for repair.

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

1. Check fan rotation and ensure fan turns clockwise as seen from the front of the heater. Refer to Section B. Installation, page 3.
2. Check fan blade set screws to ensure fan blade is not loose on the motor shaft.
3. Do not operate unit. Contact factory.

Table 4 – Recommended Torque Specifications

TECHNICAL DATA

Table 5 – Technical Data

*Note:** Barn Heaters: Approved by Manitoba Hydro for use in buildings housing livestock: c/w low watt density

GENERAL SPECIFICATIONS

Table 6 – General Specifications

*Note:* Recommended mounting height to ensure warm air reaches the floor.

HEATER MAINTENANCE CHECKLIST

Periodic (before and as required during heating season)

• Clean – Use compressed air only.
• Heating Elements
• Louvers
• Motor
• Inlet Grille
• Fan

Mounting & Motor Check

• All mounting hardware condition and tightness
• Motor for smooth, quiet operation

Annual (before heating season)

• Electrical Check
• All terminal connections and conductors. Tighten loose connections. Conductors with damaged insulation must be replaced.
• Electrical resistance on all load side legs. Reading should be balanced (± 5%).

WARNING. Disconnect heater from power supply at integral disconnect or fuse box before opening enclosures or servicing heater. Lock the switch in the “OFF” (open) position and tag the switch to prevent unexpected power application. This heater should only be serviced by qualified personnel with electrical heating equipment experience.

WARNING. 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.

Mechanical Check

• Check heating elements for corrosion and debris buildup. Clean as required.
• Check motor shaft bearing play. Replace motor if play is excessive, or if motor does not run quietly and smoothly. Bearings are permanently lubricated.
• Check fan. Replace immediately if cracked, damaged, or out of balance.
• Check tightness of all hardware. All fasteners must be tight.
• Turn heater on for a minimum of five minutes. Check for warm air exiting heater through discharge louvers.

WARRANTY

Under normal use the Company warrants to the purchaser that defects in material or workmanship will be repaired or replaced without charge for a period of 18 months from date of shipment, or 12 months from the start date of operation, whichever expires fi rst. Any claim for warranty must be reported to the sales offi ce where the product was purchased for authorized repair or replacement within the terms of this warranty. Subject to State or Provincial law to the contrary, the Company will not be responsible for any expense for installation, removal from service, transportation, or damages of any type whatsoever, including damages arising from lack of use, business interruptions, or incidental or consequential damages.The Company cannot anticipate or control the conditions of product usage and therefore accepts no responsibility for the safe application and suitability of its products when used alone or in combination with other products. Tests for the safe application and suitability of the products are the sole responsibility of the user.This warranty will be void if, in the judgment of the Company, the damage, failure or defect is the result of:

• Vibration, radiation, erosion, corrosion, process contamination, abnormal process conditions, temperature and pressures, unusual surges or pulsation, fouling, ordinary wear and tear, lack of maintenance, incorrectly applied utilities such as voltage, air, gas, water, and others or any combination of the aforementioned causes not specifi cally allowed for in the design conditions or,
• Any act or omission by the Purchaser, its agents, servants or independent contractors which for greater certainty, but not so as to limit the generality of the foregoing, includes physical, chemical or mechanical abuse, accident, improper installation of the product, improper storage and handling of the product, improper application or the misalignment of parts.
• No warranty applies to paint fi nishes except for manufacturing defects apparent within 30 days from the date of installation.The Company neither assumes nor authorizes any person to assume for it any other obligation or liability in connection with the product(s).The Purchaser agrees that all warranty work required after the initial commissioning of the product will be provided only if the Company has been paid by the Purchaser in full accordance with the terms and conditions of the contract.The Purchaser agrees that the Company makes no warranty or guarantee, express, implied or statutory, (including any warranty of merchantability or warranty of fi tness for a particular purpose) written or oral, of the Article or incidental labour, except as is expressed or contained in the agreement herein.

LIABILITY

Technical data contained in the catalog or on the website is subject to change without notice. The Company reserves the right to make dimensional and other design changes as required. The Purchaser acknowledges the Company shall not be obligated to modify those articles manufactured before the formulation of the changes in design or improvements of the products by the Company.The Company shall not be liable to compensate or indemnify the Purchaser, end user or any other party against any actions, claims, liabilities, injury, loss, loss of use, loss of business, damages, indirect or consequential damages, demands, penalties, fi nes, expenses (including legal expenses), costs, obligations and causes of action of any kind arising wholly or partly from negligence or omission of the user or the misuse, incorrect application, unsafe application, incorrect storage and handling, incorrect installation, lack of maintenance, improper maintenance or improper operation of products furnished by the Company.

Visit www.thermon.com to contact a Thermon representative near you.HEAD OFFICE: 7171 SOUTHWEST PKWY | BUILDING 300 SUITE 200 | AUSTIN, TX | 78735 | UNITED STATESRUFFNECK: 5918 ROPER ROAD | EDMONTON, AB | T6B-3E1 | CANADA

References

• World Leader in Industrial Process Heating | Thermon

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