THERMON XPA Series Explosion-Proof Panel Heater Instruction Manual

THERMON XPA Series Explosion-Proof Panel Heater Instruction

Explosion-Proof Panel Heater XPA Series
Installation, Operation, & Maintenance Instructions

**Special Notes

**

It is important to read this entire document and to keep it for future reference.
The following special notices highlight important information in the installation and maintenance sections. Each serves a special purpose and is displayed in the format shown:

• This symbol indicates a potentially hazardous situation, which, if not avoided, can result in personal injury or damage to the equipment.
• This symbol indicates a potentially hazardous situation, which, if not avoided, may be a shock hazard.
• This symbol indicates an imminently hazardous situation, which, if not avoided, could result in death or serious injury.

Specific Conditions of use:

• Heater is to be used for industrial purposes only, and is not to be used as a comfort heater
• Heater is intended to be installed in an electrical or instrumentation enclosure or equipment housing
• The connecting lead shall be installed to provide for permanent wiring and adequate protection.
• Conduit seals, where used, shall be installed immediately adjacent to the enclosure.
• The device must be installed in accordance with the manufacturer’s installation drawing number M11882. ࢦ XT-311 thermostat, where used, If replacement of the cover bolts is required, these are to be replaced with four plated steel hex head bolts, M6 x 20 mm long, property class 9.8, 720 MPa minimum yield strength.
• Peppers A3LCF cable glands, where used, are certified with one specific size of FLP sealing ring per gland size as supplied,
• Peppers A3LCF cable glands, where used, shall not be used in enclosures where the temperature at the point of entry/mounting is outside the range: -60°C to +180°C for the Silicone (white) seal variants
• Peppers A3LCF cable entries, where used, are only suitable for fixed installations. Cables must be effectively clamped to prevent pulling or twisting.
• Peppers A3LCF range of cable glands, where used, when installed in accordance with the manufacturer’s
• Hawke 501/414 glands, where used, are suitable for use within an operating temperature range of -60°C to +100°C.
• Hawke 501/414 glands, where used, for use with conduit, unarmoured or braided cables are only suitable for fixed installations, the cable for which must be effectively clamped to prevent pulling and twisting.
• Condition for non-standard joints: “The equipment has flameproof joints, which differ from those in IEC 60079-1 and are not intended to be repaired by the user.

PRODUCT CERTIFICATION

Depending on the particular model ordered, the heater is suitable for the following areas:

• CSA C/US Certified for Class I, Div 1, Groups A, B, C, D or Groups C, D, CSA Type 4; Temp. Code T2 (215°C) T2D, T3, T3B, T3C or T4
• ATEX II 2G Ex db IIC or IIB, T2 (215°C), T3 or T4, Gb IP66
• IECEx Ex db IIC or IIB, T2 (215°C), T3 or T4, Gb, IP66
  NOTE: – Standard XPA Models: -50°C to +40°C
  – High Ambient XPA Models: -50°C to +55°C or 60°C depending on model.

PRE-INSTALLATION

1. Initially, inspect the heater for possible damage due to shipping and handling. Claims for shipping damages shall be placed with the carrier.
2. Check the heater nameplate to ensure that the heater area classification and temperature code are suitable for the hazardous area classification. For details of hazardous locations with potential for explosion, refer to the Canadian Electrical Code or National Electrical Code.
3. Check to ensure that the heater voltage is the same as the supply voltage.
4. The heater must be installed by qualified personnel in strict compliance with national and local electrical codes.
   WARNING. Do not connect the heater to an electrical supply voltage other than that shown on the product nameplate.

INSTALLATION

General Requirements

1. The XPA heater is intended for industrial use and is to be mounted in an enclosure. The main function of this heater is to prevent the damaging effects of moisture and condensation on the components inside the enclosure. It is not intended for comfort heating use.
2. XPAL and XPAS heaters are approved for enclosure mounting either horizontally or side mounted with the junction box at the side. XPAR heaters are approved for vertical mounting only with the junction box at the bottom. Ensure that the enclosure is sufficiently strong to support the heater which, depending on the model, could weigh up to 15 lbs (7 kg).
3. Do not recess the XPA heater into the wall. Use the bracket supplied with the unit to ensure that the minimum spacing from the wall of 1″ (25 mm) is maintained.
4. If more than one heater is being installed, maintain at least 3″ (76 mm) between adjacent heater extrusions.
5. The XPA heater relies on natural convection and “black heat” radiation to transfer heat to the surroundings. See Table 1, page 4 for minimum clearances above heater.
   Table 1 – Minimum clearance above heater****

T-Code

|

XPAS

| XPAL

Side Mount

| XPAL

Horizontal

| XPAR

Vertical

---|---|---|---|---
in| mm| in| mm| in| mm| in| mm
T4| 6| 152| 6| 152| 6| 152| 6| 152
T3C/T3B| 6| 152| 6| 152| 9| 229| 6| 152
T3| 12| 305| 9| 229| 12| 305| 9| 229
T2D| 15| 381| 12| 305| 18| 457| 12| 305
6. Maintain a 3″ (76 mm) clearance and NEVER LESS THAN 1″ (25 mm) clearance in front of and at the sides of the heater. 7. The XPAL and XPAS heater relies on vertical convective flow through its fins to operate properly. The unit must be mounted in the horizontal or side mount orientation, as applicable. Under no circumstance can the heater be mounted vertically on its end with the junction box on the top or bottom and the flat fin surfaces in a horizontal position. The XPAR heater must be mounted vertically with the junction box at the bottom. Refer to Figure 11– Figure 13, page 5 for allowable mounting orientations.
CAUTION. The heater’s surface is hot when the heater is energized. Keep all combustibles away from the heater and maintain the recommended installation clearances at all times.

Mounting Bracket Installation: XPAL & XPAS Heaters
Install heater with the supplied hardware in accordance with the figures and instructions below (Figure 14 and Figure 15, page 6).

• Step 1: Scribe lines into the mounting surface signifying the top and side of the mounting bracket, indicating where the mounting bracket will be located after installation (Figure 4 and Figure 5, page 4)
• Step 2: Remove the mounting bracket from the heater and install it to the mounting surface, aligning the bracket with the scribe marks from Step 1 (Figure 6, page 4)
• Step 3: Secure the heater to the bracket by tightening the provided Socket Head Cap Screws into the threaded holes on each end of the heater (Figure 7, page 4).

Mounting Bracket Installation: XPAR Heaters

• Step 1: Scribe a mark into the mounting surface indicating where the top part of the mounting bracket will be located after installation (Figure 5, page 4).
• Step 2 : Measure down 0.625” (16 mm) from the scribed mark and scribe a mark for the top bolt location. Measure an additional 5.5” (140 mm) from the top bolt location to indicate the bottom bolt location (Figure 9, page 4). Drill holes at the marked locations for the mounting bolts.
• Step 3: Pre-install the mounting bolts onto the mounting surface allowing enough clearance to slide the mounting bracket under the head of the supplied bolts. Position the heater onto the mounting bolts and tighten securely (Figure 10, page 5).

NOTE: Proper use of supplied mounting bracket will ensure minimum distance of 1” (25 mm) from the mounting surface.

• CAUTION. Never install one heater above the other.
  To ensure safe operation, heater must be installed as shown in Figure 11– Figure 13, page 5). Installation with fins in the incorrect orientation may result in an unsafe condition (refer to Table 2, page 6)

Figure 13 – XPAR heater mounting orientations (vertical only)
Figure 14 – XPAL and XPAS heater basic mounting drawing

Table 2 – Mounting orientation (Standard XPA Models)

 |  |  | Class I, Div 1& 2, see notes for Groups| Weight|
---|---|---|---|---|---
Length| Wattage| Fig. No.|  |  |  |  |  | Part No.
 |  |  | T2/T2D| T3| T3B/T3C| T4| lbs (kg)|

4.375”

(111 mm)

| 75| 12| | | | |

7.4 (3.4)

| XPAS-075
100| 12| | | | –| XPAS-100
125| 12| | | | –| XPAS-125
150| 12| | | –| –| XPAS-150
200| 12| | | –| –| XPAS-200
250| 12| | –| –| –| XPAS-250

9”

(229 mm)

| 100| 12| | | | |

12.8 (5.9)

| XPAL-100
150| 12| | | | | XPAL-150
200| 12| | | | | XPAL-200
250| 11 or 12| | | | Horizontal Only| XPAL-250
300| 12| | | | –| XPAL-300
400| 11 or 12| | | Horizontal Only| –| XPAL-400
500| 12| | | –| –| XPAL-500
600| 11 or 12| | Horizontal Only| –| –| XPAL-600
700| 11| Horizontal Only| –| –| –| XPAL-700

7”

(178 mm)

| 50| 13| Vertical Only| Vertical Only| Vertical Only| Vertical Only|

3.8 (1.7)

| XPAR-050
80| 13| Vertical Only| Vertical Only| Vertical Only| –| XPAR-080
125| 13| Vertical Only| Vertical Only| –| –| XPAR-125
150| 13| Vertical Only| –| –| –| XPAR-150

NOTE: Groups A, B, C & D, IIC apply when XJB-4 and XTWA junction boxes. Groups C & D, IIB apply when using XT-311 and XT-411 junction boxes with adjustable thermostats.

Table 3 – High Ambient XPA Models

Length

|

Wattage

|

Fig. No.

| Temperature Code|

Part No.

---|---|---|---|---
T2D(1)| T3| T3A| T3C

4.375”

(111 mm)

| 75| 12| | | | | XPASH-075
100| 12| | | | n/a| XPASH-100
125| 12| | | | n/a| XPASH-125
150| 12| | n/a| n/a| n/a| XPASH-150
200| 12| | n/a| n/a| n/a| XPASH-200

9”

(229 mm)

| 100| 12| | | | | XPALH-100
150| 12| | | | | XPALH-150
200| 12| | | | | XPALH-200
250| 11 or 12| | | | Horizontal Only| XPALH-250
300| 12| | | | n/a| XPALH-300
400| 11 or 12| | Horizontal Only| Horizontal Only| n/a| XPALH-400
500| 12| | n/a| n/a| n/a| XPALH-500
600| 11| Horizontal Only| n/a| n/a| n/a| XPALH-600

7”

(178 mm)

| 50| 13| Vertical| Vertical| Vertical| Vertical| XPARH-050
80| 13| Vertical| Vertical| Vertical| n/a| XPARH-080
125| 13| Vertical| n/a| n/a| n/a| XPARH-125

NOTE:

1. T2D models are rated for 55°C maximum ambient temperature.
2. All other heaters are rated for 60°C maximum ambient temperature.
3. High ambient units only available with XJB-4 junction box.

WIRING

General

1. Whenever hazardous materials are present, ensure that the junction box covers are secure before energizing the heater. Follow all applicable national and local codes for hazardous location installation. The XPA heater is available with a terminal housing. A terminal housing may be required by national and/or local codes for hazardous locations.

2. Use supply wires suitable for 221°F (105°C) for standard units or 257°F (125°C) for hight ambient units.

3. The connecting supply wires shall be installed to provide for permanent wiring and have adequate protection against mechanical damage.

4. Use approved conduit and conduit seals as required by the national and local codes for hazardous locations.

5. To provide maximum protection, each XPA heater should be fused individually using HRC fuses.

6. All heaters come factory prewired ready for direct connection to power supply leads (see Figure 16, ).
   Connect the power leads to terminals marked L1 and N or L2.
   Connect the ground wire to the ground connection located in the heater junction box cover.

7. Replace junction box cover securely. Do not over-tighten.

8. For Cable Only XPA Units, heaters must be installed to an unisulated grounded metal surface with the mounting bracket supplied. Please refer to national and/or local electrical codes for proper grounding installation in hazardous locations.

• WARNING. Whenever hazardous materials are present, ensure that the terminal housing covers, plugs, etc,. are secured (but not over-tightened) before energizing the heater.
• CAUTION. All circuits must be in the open position before removing junction or terminal box covers.
• CAUTION. Use supply wires suitable for 221°F (105°C) or 257°F (125°C). Supply wires are to be fused appropriately size HRC fusing.
• WARNING. Use approved conduit and conduit seals as required by hazardous location standards.
• CAUTION. Ensure that no power is connected to the equipment prior to making any connections.

Wire Guard (optional)
Install wire guard by inserting wire arms into holes on heater fins.

START-UP

1. If the unit contains a junction box ensure the junction box lid is securely installed onto the terminal housing.
2. Check to ensure that all plugs, screws, and covers are securely in place.
3. Check associated electrical equipment.
4. Check that all wall mounting bracket connections are tight.
5. Turn on supply power.
6. If the unit is equipped with an adjustable thermostat, dial the temperature required by twisting the thermostat knob.
   WARNING. To prevent unsafe operation of the heater do not exceed the maximum allowable ambient operating temperature of 104°F (40°C).
   WARNING. To prevent unsafe operation of the heater do not exceed the maximum allowable ambient operating temperature of 55°C or 60°C on high ambient units.

MAINTENANCE

Check the following before every heating season:

• WARNING. Disconnect power from the heater before performing any maintenance. Failure to do so can result in property damage, injury, or death.
• WARNING. Painted and anodized surfaces have a potential risk of electrostatic discharge. Do not use a dry cloth to clean this device, use only a damp cloth.

1. Remove junction box cover and inspect the electrical connections. Ensure the connections are tight and wires are not burned or frayed.
2. Inspect the heater and its surroundings. Make sure that heater clearances are maintained and no debris is around the heater or stuck in the fins.
3. Check all mounting hardware and ensure fasteners are tight.
4. Replace the cover securely and turn on the power supply.

REPAIRS

1. If the heater malfunctions, and is no longer operating, send the heater to the factory for servicing. Do not attempt to service the unit.

2. Thermostat cover bolts must be replaced with four plated steel hex headbolts, M6 x 20 mm long, property class 9.8, 720 MPa minimum yield strength.

3. When returning the heater you can fill out the online repair form at: http://www.thermon.com/online-repair-form.php
   Or, include the following information with the heater when shipping:

   • Company name and address
   • Contact name
   • Telephone/fax number/email
   • Product model and serial numbers
   • Tagging codes
   • Advise if an estimate is required prior to starting the repair
   • .O. Number
   • Description of problem(s) and/or require repairs
   • Special instructions (if applicable)
   • Return shipping instructions

TROUBLESHOOTING

WARNING. Only open the junction box if it is safe to do so!
These heaters contain a thermal fuse. If the unit is not operating within proper constraints, the unit may have overheated, causing the thermal fuse to open. Check the thermal fuse by disconnecting the power, opening the junction box and measuring the resistance across the terminals. If the resistance is infinite, the fuse has been triggered and the unit must be sent to Thermon, for repair.

NOTE: If your circuit contains a thermostat and the ambient temperature is high enough to turn off the thermostat, the measured resistance will be infinite, this test will not check the thermal fuse.
For further assistance, please call 24hr hotline: 1.800.661.8529 (U.S.A. and Canada) Please have model and serial numbers available before calling.

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.

Edmonton
1-800-661-8529 1-780-466-3178 F 780-468-5904
Oakville
1-800-410-3131 1-905-829-4422 F 905-829-4430
Orillia
1-877-325-3473 1-705-325-3473 F 705-325-2106
Houston
1-800-654-2583 1-713-433-2600 F 713-433-4541
Denver
1-855-244-3128 1-303-979-7339 F 303-979-7350

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