EK SERIES Electric Duct Heater

Installation, Operation and Maintenance Manual

EK Series for Commercial Indoor Applications

EK Series shown
 ACCESSORY EK-Series Electric Duct Heater
WARNING
Arc flash and electric shock hazard
Arc flash and electric shock hazard. Disconnect all electric
power supplies, verify with a voltmeter that electric power
is off and wear protective equipment per NFPA 70E before
working within electric control enclosure. Failure to comply can
cause serious injury or death.
Customer must provide earth ground to heater, per NEC, CEC
and local codes, as applicable.
Before proceeding with installation, read all instructions, veri-
fying that all the parts are included and check the nameplate to
be sure the voltage matches available utility power.
The line side of the disconnect switch contains live high-volt-
age.
The only way to ensure that there is NO voltage inside the
heater is to install and open a remote disconnect switch and
verify that power is off with a volt meter. Refer to unit electrical
schematic. Follow all local codes.
2 1.800.627.4499
CAUTION
Risk of contact with HOT SURFACES
This heater, including the heating elements and their support
structure are extremely hot during operation. Allow sufficient
time for them to cool before working within the cabinet. Use
extreme caution and wear protective gloves and arm protection
when working on or near the heater.
CAUTION
Risk of electric shock or equipment damage
Whenever electrical wiring is connected, disconnected or
changed, the power supply to the heater and its controls must
be disconnected. Lock and tag the disconnect switch or circuit
breaker to prevent accidental reconnection of electric power.
 OWNER INFORMATION
EK-Series Electric Duct Heater ACCESSORY

SAVE THIS MANUAL

UNIT RECORDS
Record information as shown below. In the unlikely event that factory assistance is ever
required, this information will be needed.
Locate the RenewAire unit label, found on the door of the electric duct heater.
NOTE: This information is for purposes of identifying the specific furnace. Unit-specific option
data can then be obtained, as needed, from the Model Number. See Electric Heater Code in this
manual for further details.

Heater Model No: NOTE: This page

is to be completed
Serial Number: by the installing
contractor. The completed
SO Number: document is to be turned
over to the owner after
start-up.

ELECTRIC DUCT HEATER

MODEL NUMBER

SERIAL NUMBER

SO#

TYPICAL ELECTRIC DUCT HEATER LABEL

1.800.627.4499 3
 OPTIONS & ACCESSORIES

EK SERIES Electric Duct Heater (1-175 kW)

Accessory

ELECTRIC DUCT HEATER SPECIFICATIONS

Heater Type: Voltages & Phase:
Electric Duct Heater Single phase - 120, 208, 240, 277
Typical KW Range: Three phase - 208, 240, 480, 600
1–175 kW Control Voltage:
Standard Features: 24 VAC
A disconnecting magnetic control contactor per Dimensions:
stage or each 48 Amp circuit within a stage Minimum - 8" x 8" (W x H)
Open-coil element Maximum - 99" x 99" (W x H)
Staged on/off Options:
Control terminal board Flange mount
Grounding lugs 80-20 (Ni/Cr) A Grade element wire with
Automatic limit switch for primary over- stainless steel terminals
temperature protection Recessed control box 1"
Manual reset limit switch for secondary over- Gasketed cover - dust tight
temperature protection Power fusing, standard for heaters drawing more
Download specification at: Non-adjustable airflow switch than 48 Amps
renewaire.com/specifications Standard control transformer - 24 VAC 2-stage
Disconnect switch Electronic step controller (4-stage)
Duct thermostat with sensor for on/off control SCR (up to 96 Amps)
60-20-20 (Ni/Cr/Fe) C Grade element wire with SCR Vernier (over 96 Amps)
nickel-plated terminals Pilot light
Slip-in mount
Accessory:
No left/right hand
Room thermostat
Vertical up/down flow
Room/duct thermostat-sensor kit for SCR control
Note: Electric duct heater designed for indoor ductwork installation only.

EK Series
EK SERIES Heater Capacity
HEATER CAPACITY
PRESSURE DROP THROUGH HEATER
PRESSURE DROP THROUGH HEATER
200
0.18
4
Static Pressure Drop - Inches of Water

175 0.16

0.14
150
3
HEATER CAPACITY - kW

0.12
125
0.1

100 0.08 2
0.06
75
0.04
SAFE OPERATING
50 RANGE 0.02
1

25 0
0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200
0 Air Velocity - FPM (1, 2, 3 and 4 - the number of rows of heater coils)
0 2500 5000 7500 10000 12500
When the number of rows of heater coils is unknown, assume 4.
AIRFLOW - CFM

p g

HORIZONTAL DUCT & AIRFLOW VERTICAL DUCT & AIRFLOW

with HORIZONTAL INSTALLATION

BASE HEATER
FLIPPED 180°
AIR DUCT
AIRFLOW

SLIP-IN

FLIPPABLE
CONSTRUCTION
SHOWN

CAPABILITIES AIR
FL
OW
BASE
HEATER

. Unique to the EK series, this unit has the ability

to flip 180°. Additionally, EK heaters features
both vertical up and vertical down airflow. BASE AIR
AIRFLOW

HEATER FL
OW

BASE
HEATER
ROTATED * ONE HEATER- 4
180o POSITIONS * SAME HEATER- FOR
VERTICAL DUCTS

FIGURE: 4

Specifications may be subject to change without notice.

FOR THE MOST COMPLETE AND CURRENT INFORMATION VISIT RENEWAIRE.COM 133

4 1.800.627.4499
 TECHNICAL DATA

PRODUCT DIMENSIONS ABBREVIATIONS

ELECTRIC DUCT HEATER W Width
OFFSET RIGHT H Height
OPTIONAL R

Q* TYPE S SLIP-IN
N
BD* R
F
U T* Q*
N
M*
Z* BD*
F
U T*
H
W
M*
Z*
H
TYPE F FLANGE MOUNT
W

OFFSET LEFT
* = Dimensions do not include allowance for
control box cover. Control box cover will STANDARD
be larger than the control box.

NOTES:
ITEM QTY SERIES KW PH VOLTS STG CTL VLT S/F KW/STG W H Q Z U BD F R N T M
1. W and H determined by duct size 5. T = 1" standard
A. F or slip-in 6. M = 1" standard
W = Duct width minus 1/4 inch 7. Q
 = (12" minimum) Size depends on required components.
H = Duct height minus 1/16 inch Consult factory for dimensions
B. flange mount 8. F = 9/16" for slip-in type
1.WW andandH=Duct size
H determined by duct size Z = (H+2" standard for slip in) (H+4" for flange mount)
1" for flange4.mount
2. U
 = (W+H Up to 60"=4 7/8), (61" and over U=6")
A. For slip-in 9. R 5.
 = 1 1/2" when = T using 4 7/8" U dimension
1" standard
(W greater W than=36" U=6")
Duct width minus 1/4 inch 6. dimension
15/16" when using 6"1"U standard
M =
3. BD = 4 1/4, 6, 8 1/2, or 10 1/4 depth
H = Duct height minusof control box depends on the
1/16 inch 10. N = Q minus 7. RQand U
= (12" minimum) Size depends on required components.
components required and size of power entry holes
B. flange mount Consult factory for dimensions
4. Z = (H+2" standard for slip in) (H+4"
W and H=Duct size for flange mount) 8. F = 9/16" for slip-in type
2. U = (W+H Up to 60"=4 7/8), (61" and over U=6") 1" for flange mount
NOTE: R and N dimensional values exchange position for right hand offset.
(W greater than 36" U=6") 9. R = 1 1/2" when using 4 7/8" U dimension

1.800.627.4499
3. BD = 4 1/4, 6, 8 1/2, or 10 1/4 depth of control box 15/16" when using 6" U dimension

5
depends on the components required and size 10. N = Q minus R and U
of power entry holes

Note: R and N dimensional values exchange position for right hand offset.
 TABLE OF CONTENTS
ACCESSORY EK-Series Electric Duct Heater

1.0 OVERVIEW 11 6.0 OPERATING INSTRUCTIONS 28

1.1 DESCRIPTION�������������������������������������������������������11 6.1 ELECTRICAL REQUIREMENTS��������������������������������28
1.2 ELECTRICAL SUPPLY���������������������������������������������11 6.2 GENERAL OPERATING REQUIREMENTS������������������28
1.3 HEATER CAPACITY IN KILOWATTS�������������������������12
7.0 MAINTENANCE 29
1.4 HEATER ELEMENTS����������������������������������������������12
7.1 SERVICE PARTS����������������������������������������������������29
1.5 SAFETY FEATURES�����������������������������������������������12
1.5.1 Airflow Switch������������������������������������������������������������������ 12
1.5.2 Automatic Reset Limit Switch������������������������������������������� 12 8.0 FACTORY ASSISTANCE 30
1.5.3 Manual Reset Limit Switches�������������������������������������������� 12
1.6 HEATER CONTROL������������������������������������������������13
1.7 HEAT RISE������������������������������������������������������������13
1.8 USER INTERFACE�������������������������������������������������13

2.0 SYSTEM REQUIREMENTS 14

2.1 GENERAL OPERATING REQUIREMENTS������������������14
2.2 SIZING AN ELECTRIC DUCT HEATER����������������������14
2.3 AMPERAGE DRAW������������������������������������������������14
2.4 KW AND TEMPERATURE RISE��������������������������������14
2.5 DUCT HEATER TEMPERATURE RISE�����������������������14
2.6 DETERMINING MAXIMUM HEATER KW�������������������14
2.7 MINIMUM AIR VELOCITIES������������������������������������15

3.0 HEATER PLACEMENT  16

3.1 GENERAL�������������������������������������������������������������16

4.0 ELECTRICAL DATA 19

4.1 TYPICAL CONTACTOR POWER CIRCUITRY��������������19
4.2 HEATING ELEMENT WIRING CONFIGURATIONS AND
PROPERTIES��������������������������������������������������������������19
4.3 HEATER WIRING SCHEMATICS�������������������������������20
4.4 LOW VOLTAGE CONTROL SYSTEM������������������������������22
4.4.1 Specifications�������������������������������������������������������������������22
4.4.2 Limits of Power Output�����������������������������������������������������22
4.5 LOW VOLTAGE CONTROLS CONNECTION������������������23
4.5.1 Interface Module Control Signal Wiring Connection Diagram
�������������������������������������������������������������������������������������������������23
4.5.2 Electronic Step Controller or SCR Control�������������������������� 24
4.5.3 Staged Control�����������������������������������������������������������������25

5.0 INSTALLATION 26
5.1 PLACEMENT OF THE ELECTRIC DUCT HEATER�������26
5.2 HEATER INSPECTION��������������������������������������������26
5.3 DUCT INSTALLATION���������������������������������������������27

6 1.800.627.4499
 TABLE OF CONTENTS
EK-Series Electric Duct Heater ACCESSORY

TABLE OF ILLUSTRATIONS
Figure 1.1.0 Electric Heater (typical)������������������������������������������������������������������������������������������������������� 11
Figure 1.1.1 Control Panel Cover������������������������������������������������������������������������������������������������������������ 11
Figure 1.1.2 Basic Control Panel������������������������������������������������������������������������������������������������������������� 11
Figure 1.5.0 Heater Controls Identification��������������������������������������������������������������������������������������������� 12
Figure 1.7.0 Heat Rise Calculation���������������������������������������������������������������������������������������������������������� 13
Figure 2.7.0 FPM vs. KW / Ft.2 Chart���������������������������������������������������������������������������������������������������� 15
Figure 3.1.0 Placement: Minimum Airflows��������������������������������������������������������������������������������������������� 16
Figure 3.1.1 Placement: Elbow Minimum Requirement���������������������������������������������������������������������������� 16
Figure 3.1.2 Placement: Location Requirements������������������������������������������������������������������������������������� 16
Figure 3.1.3 Placement: Transition Requirements����������������������������������������������������������������������������������� 17
Figure 3.1.4 Placement: Downstream Requirements������������������������������������������������������������������������������� 17
Figure 3.1.5 Placement: Humidifier Requirements����������������������������������������������������������������������������������� 17
Figure 3.1.6 Placement: Air Filter Requirements������������������������������������������������������������������������������������� 17
Figure 3.1.7 Placement: Obstruction Requirements��������������������������������������������������������������������������������� 18
Figure 3.1.8 Placement: Control Box Requirements��������������������������������������������������������������������������������� 18
Figure 3.1.9 Placement: Double Blower Requirements���������������������������������������������������������������������������� 18
Figure 4.1.0 Typical Contactor Power Circuitry���������������������������������������������������������������������������������������� 19
Figure 4.2.0 Heating Element Wiring Properties�������������������������������������������������������������������������������������� 19
Figure 5.3.0 Slip-in Heater Installation��������������������������������������������������������������������������������������������������� 27
Figure 5.3.1 Flange Heater Installation��������������������������������������������������������������������������������������������������� 27
Figure 5.3.2 Common Installation Approaches���������������������������������������������������������������������������������������� 27
Figure 7.1.0 Service Parts���������������������������������������������������������������������������������������������������������������������� 29

TABLE OF WIRING SCHEMATICS

Figure 4.3.0 Single Phase On-Off Heater Wiring������������������������������������������������������������������������������������� 20
Figure 4.3.1 Single Phase SCR Heater Wiring����������������������������������������������������������������������������������������� 20
Figure 4.3.2 Three Phase On-Off Heater Wiring�������������������������������������������������������������������������������������� 21
Figure 4.3.3 Three Phase SCR Heater Wiring������������������������������������������������������������������������������������������ 21
Figure 4.5.0 Stand Alone Thermostat for Modulating Control������������������������������������������������������������������ 23
Figure 4.5.1 DDC BAS for Modulating Control (2-10Vdc)�������������������������������������������������������������������������� 23
Figure 4.5.2 DDC BAS for Modulating Control (4-20mA)������������������������������������������������������������������������� 23
Figure 4.5.3 Viconics Room Thermostat without Remote Sensor for Modulating Control�������������������������� 24
Figure 4.5.4 Viconics Room Thermostat with Remote Sensor for Modulating Control for Return Air���������� 24
Figure 4.5.5 Viconics Room Thermostat with Remote Sensor for Modulating Control for Supply Air��������� 24
Figure 4.5.6 Single Stage Thermostat with Remote Sensor for On/Off Control����������������������������������������� 25
Figure 4.5.7 2-Stage Thermostat with Remote Sensor for On/Off Control������������������������������������������������ 25

1.800.627.4499 7
 CONFIGURATION CODE
ACCESSORY EK-Series Electric Duct Heater

ELECTRIC DUCT HEATER CONFIGURATION CODE

Each RenewAire Electric Duct Heater is assigned a 25 digit Model Number. The Model Number
can be used to identify the various options as ordered by the customer.

MODEL NUMBER
-
DIGIT NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

Digits 1 - 2: Heater Type Digit 18: Voltage (see Restrictions 7 & 8)

"EK "= Electric Heater (Standard) "1" = 120V
"2" = 208V
"3" = 240V
Digits 4 - 5: Width in Inches (see Restriction 1) "4" = 480V
08-99 "8" = 600V
"9" = 277V
Digits 6 - 7: Height in Inches (see Restriction 2)
Digit 19: Phase
08-99
"1" = Single-Phase
Digits 8 - 10: Capacity in kW (see Restrictions 3, 4 & 5) "3" = Three-Phase
001-175
Digit 20: Power Fusing (see Restriction 9)
Digit 11: Mount "-" = None
"F" = Fusing
"S" = Slip In (Standard)
"F = Flanged
Digit 21: Stage
Digit 12: Element Style "1" = Single (Standard)
"2" = 2-Stage
"C" = Open Coil (Standard)
"4" = 4-Stage
Digit 13: Element Material
Digit 22: Control Voltage
"C" = 60-20-20 Ni-Cr-Fe with Nickel Plate Terminal Pins (Standard)
"A" = 80-20 Ni-Cr with Stainless Steel Terminal Pins "S" = 24VAC

Digit 14: Airflow Orientation Digit 23: Control Type (see Restrictions 10, 11 & 12)
"H" = Horizontal (Standard) "D" = Staged with Thermostat and Sensor (Standard)
"V" = Vertical "E" = Electronic Step Control with Thermostat and Sensor
"S" = SCR (control by others)
Digit 15: Control Box Offset "V" = SCR with Thermostat and Sensor
"L" = Left Hand (Standard)
"R" = Right Hand Digit 24: Time Delay
"-" = None (Standard)
Digit 16: Control Box Recessed
"-" = None (Standard) Digit 25: Pilot Light (See Restriction 13)
"R" = Recessed 1"
"N" = None (Standard)
"L" = Light
Digit 17: Control Box Dust Tight
"-" = None (Standard)
"D" = Dust Tight

*NOTES:
Digit 3 is not used in this model.
All heaters come with standard features: Disconnect Switch, Air Flow Switch (non adjustable), Control Transformer
Descriptions of feature and options are found in the installation and operation manual.
Restrictions:
1: Width inches entered as a whole number.
2: Height inches entered as a whole number.
3: Heater density should be less than 30kW/ft². DENSITY= HEATER CAPACITY (kW) < 30
(W" x H")/144
4: Heater capacity kW entered as a whole number.
5: Formulas for calculating kW and temperature rise: kW = CFM x ΔT ΔT = kW x 3150
3150 CFM
7: Voltage Codes "1" & "9" only available with Phase Code "1" (Single-Phase).
8: Voltage Codes "4" & "8" only available with Phase Code "3" (Three-Phase).
9: Power Fusing Code "F" required when amperage is >48A. (based on kW and voltage)
10: Control Type Code "D" only available with Stage Code "1" & "2".
11: Control Type Code "E" only available with Stage Code "4".
12: Control Type Code "S" & "V" only available with Stage Code "1", unless amperage is greater than or equal to 96A, then Stage Code "4" is automatically selected.
13: Pilot Light Code "L" only available with Control Type Code "D".

ELECTRIC POST HEAT

8 1.800.627.4499 CONFIGURATION CODE CHART

DEFINITIONS FOR CONFIGURATION CODE
Heater Type:
EK—(Standard) heater 8"–99" height and
width.
Width:
W—Width of duct ID in inches. For slip-in
type the W dimension is undersized by ¼" to
allow heater to slip into ductwork.
Range 8"–99"
Height:
H—Height of duct ID in inches. For slip-in
type the H dimension is undersized by 1/16"
to allow heater to slip into ductwork.
Range 8"–99"
Capacity:
KW—Kilowatt rating of heater. Determined by
airflow (CFM) and temperature rise (rT).
Range 1–175 KW
Mount:
Slip-in (Standard)—heater is installed through
opening cut into side of duct and the control
box is attached to duct.
Flanged (Option)—heater is installed between
two sections of flanged duct and bolted in
place.
Element Style:
Open Coil (Standard)—open coil resistance
wire. Used in most applications.
Element Material:
60-20-20 NI-CR-FE with nickel plate terminal
pins (Standard)—standard “C” grade element
wire. 60% nickel, 20% chromium, 20% iron.
80-20 NI-CR with stainless steel terminal pins
(Option)—premium “A” grade element wire.
80% nickel, 20% chromium.
Airflow Orientation:
Horizontal (Standard)—heater installed where
airflow in ductwork is horizontal through the
heater.
Vertical (Option)—heater installed where
airflow in ductwork is vertical through the
heater. Vertical up and down airflow available
in EK series.
CONFIGURATION CODE
EK-Series Electric Duct Heater ACCESSORY
Control Box Offset:
Left Hand (Standard)—the control panel is
offset to the left side of the heating elements
as determined when looking into the control
box.
Right Hand (Option)—the control panel is
offset to the right side of the heating elements
as determined when looking into the control
box.
Control Box Recessed (Option):
Recessed 1"—Control box is designed
to extend 1" beyond internally insulated
duct. Heater element width construction is
automatically reduced by 1". Heater element
height construction is automatically reduced
by 2". Recess depth dimension is 1". Only
allowed for internally insulated ducts of 1"
insulation thickness.
Control Box Dust Tight (Option):
Dust Tight—Compression type gasket
installed on control box flanges to seal door
opening. Control box seams are filled to
prevent dust intrusion. Typically specified
when local code requires it.
Voltage and Phase:
Single Phase—120V, 208V, 240V, 277V
3-Phase—208V, 240V, 480V, 600V
Power Fusing:
Required by UL and NEC if amperage is over
48A. Otherwise is an option.
Stage:
Single Stage (Standard)—All heating
elements are energized simultaneously. SCR
control is always single stage.
2-Stage (Option)—Heating capacity is divided
into two sections. Half of the heating capacity
can be energized when less heating is
required. Both stages are energized when full
heating is required. Can be for on/off control.
4-Stage—Heating capacity is divided into
four sections. 4-stage for Electronic Step
Control only.
Control Voltage:
24 VAC (Standard)—secondary voltage
1.800.627.4499 9
 CONFIGURATION CODE
ACCESSORY EK-Series Electric Duct Heater

Control Type: Airflow Switch: (Standard)

Duct Thermostat with sensor—standard Non-adjustable pressure switch that prevents
thermostat with on/off control. Sensor is duct the heater from being energized when no
mounted. Thermostat must be programmed by or very low air flow is present through the
installer for the number of stages. (Standard) heater. Minimum air flow pressure is 0.05
Electronic Step Control—provides sequencing in.w.c + .02.
control in steps of 4 for duct heater. Converts Auto Reset: (Standard)
analog input signal into discrete steps or Automatic reset limit switch for primary
stages. As an example, if you have a 4-stage over-temperature protection. Required by UL.
heater the step controller would be 4-stage.
For an analog signal greater than 4Vdc the Manual Reset: (Standard)
first stage would energize, for an analog Manual reset limit switch for secondary
signal greater than 6Vdc the first and second over-temperature protection. Required by UL.
stages would energize, for an analog signal
Disconnect Switch: (Standard)
greater than 8Vdc the first, second, and third
stages would energize, and for an analog Non-fused interlocking switch mounted in the
signal at 10Vdc all stages would energize. door of the heater control box. Must be turned
off to open door on control box. Interrupts
Silicon Controlled Rectifier (SCR)—100%
power to the heater when turned off.
step-less modulating control. Accepts
0-10Vdc or 4-20mA as control signal. Utilizes Terminal Block: (Standard)
solid state relays (SSR) to switch current to Low voltage control terminal block included.
the heating elements, on a time-proportioned
basis. Ground Lug: (Standard)
SCR Vernier—When SCR control is selected Connection point for grounding field
and the heater is greater than 96A then an connected line voltage.
SCR vernier control is implemented. This All heaters are designed for zero clearance.
combines an SCR with 4-stage electronic
Control box is constructed of galvanized steel.
step control as a cost effective method for
providing modulating control on heaters Control box has hinged access door with
greater than 96A. interlocking disconnect switch.
A SSR is an electronic switching device similar All heaters are UL and cUL listed and tested in
to an electromechanical relay (contactor) accordance with Standard UL1996.
but has no moving parts which allows very
fast switching of high current loads without
arcing or wearing out. A heater with an SCR
controller must be installed in such a way
as to provide good ventilation to the heat
sink so that the life of the SSR is prolonged.
Over-heating of an SSR causes it to fail so the
heater must be installed such that the heat
sink is positioned either vertically on the side
of the control cabinet or on top of the control
cabinet—never on the bottom.
Pilot Light Option:
Light to indicate heater energized. Control
voltage same as transformer secondary
voltage (24 VAC).

10 1.800.627.4499
 OVERVIEW
EK-Series Electric Duct Heater ACCESSORY

1.0 OVERVIEW
1.1 DESCRIPTION
The model EK electric duct heater is an open-coil type heater for indoor installation only.
Multiple voltages and heater sizes are offered. A number of different control options are offered.

FIGURE 1.1.0 ELECTRIC HEATER (TYPICAL)

FIGURE 1.1.1 CONTROL PANEL COVER

FIGURE 1.1.2 BASIC CONTROL PANEL

1.2 ELECTRICAL SUPPLY

The electric duct heater requres both line voltage and low voltage circuits with correct polarity
and clean neutral and ground. Line voltage readings between each leg should be within +/- 3
volts of the voltage rating on the heater rating label, found on the door of the control panel.

1.800.627.4499 11
 OVERVIEW
ACCESSORY EK-Series Electric Duct Heater

1.3 HEATER CAPACITY IN KILOWATTS

Electric heater capacity is based on kilowatts (kW). Electric heaters are nearly 100% efficient,
so output capacity equals input capacity. Heaters are available in capacities from 1 - 175 kW.
1.4 HEATER ELEMENTS
A choice of two different types of heater elements is offered: either 60–20–20 Ni–Cr –Fe with
nickel plated terminal pins (standard) or 80-20 Ni-Cr with stainless steel terminal pins.
1.5 SAFETY FEATURES
Each heater is equipped with the following:
1.5.1 Airflow Switch
The airflow switch is a non-adjustable pressure switch that prevents the heater from being
energized when no or very low air flow is present.
1.5.2 Automatic Reset Limit Switch
The auto reset limit switch is mounted on the heater next to the elements. If the limit switch
detects temperatures greater than 130 degrees Fahrenheit [54.4 0 C], it shuts down the heater
until the temperature drops and then the limit switch automatically resets itself.
1.5.3 Manual Reset Limit Switches
There are two manual reset limit switches on the heater, located next to the heater elements. If
the limit switch detects temperatures in excess of 200 degrees Fahrenheit [93.3 0 C], the limit
switch trips and shuts off the heater. The limit switch must be manually reset.

AUTO RESET MANUAL RESET

LIMIT SWITCH LIMIT SWITCHES

AIRFLOW SWITCH
PROBE

CONTACTORS

SIGNAL INTERFACE
MODULE (SIM)
DISCONNECT SOLID STATE
SWITCH RELAY (SSR)

LIMIT SWITCHES

AIRFLOW
SWITCH
FIGURE 1.5.0 HEATER CONTROLS IDENTIFICATION

12 1.800.627.4499
 OVERVIEW
EK-Series Electric Duct Heater ACCESSORY

1.6 HEATER CONTROL

Electric duct heaters are configured with either staged or modulating control. The options
available are:
u Single Stage
u 2-stage
u 4 -stage
Single stage control is when all heating elements are energized simultaneously. Single stage
control can be either simple ON/OFF or modulating.
2-stage control has the heating capacity divided into two sections. Half of the heating capacity
is energized when less heating is required. Both stages are energized when full heating is
required. 2-stage control is always ON/OFF.
4-stage control is when the heating capacity is divided into four sections. This provides
sequencing control in four steps for the heater. The heater controller converts an analog input
signal into discrete steps or stages to energize each stage of the heating elements. 4-stage
control is always Electronic Step Control.

1.7 HEAT RISE

u Maximum allowable discharge temperature is 120˚ F [48.9˚ C] for any installation.
u Maximum allowable temperature rise is 90˚ F [50˚ C].
u Maximum design duct static pressure is 3.0 InWC .
Note that the example below is based upon a specific Entering Air temperature. As Entering Air
temperatures vary, the resulting temperature rise will also vary.

3000 CFM
30 kW 76 ˚F
45 ˚F Entering Input Discharge
Air Temp 31.5 ˚ F Rise Air Temp

FIGURE 1.7.0 HEAT RISE CALCULATION

1.8 USER INTERFACE

The User Interface (U/I) is the device used to control operation of the electric duct heater.
Single and 2-stage heaters are ordered with a 2-stage duct thermostat and sensor. Modulating
heaters can be ordered with an analog thermostat and sensor. The user interface may be a
simple ON/OFF thermostat, modulating thermostat, or even a Building Management System
(BMS).

1.800.627.4499 13
SYSTEM REQUIREMENTS
ACCESSORY EK-Series Electric Duct Heater

2.0 SYSTEM REQUIREMENTS

2.1 GENERAL OPERATING REQUIREMENTS
Minimum Air Velocity: 70 CFM per KW (75-80 Recommended)
Maximum Inlet Air Temp: 100 Deg. F [37.80 C]
Maximum Heater KW: 3 0 kW per square foot of heater cross section.

2.2 SIZING AN ELECTRIC DUCT HEATER

An electric duct heater can be sized from the following information:
NOTE: The air u Duct Width (W") and Duct Height (H")
temperature u Heater voltage and phase
entering the heater
should not exceed
u Heater Capacity rating (kW)
that marked on the heater u Or Design Air Flow (CFM) and
nameplate label. u Desired Temperature Rise (∆ °F)
2.3 AMPERAGE DRAW
Any electric duct heater with line current over 48 amps automatically receives fusing per UL
and NEC requirements. Electric duct heaters over 48 amps are subdivided into loads less than
48 amps. Formula for calculating line current are:
Single Phase: Amps = Watts/Line Voltage
Three Phase: Amps = Watts/(Line Voltage x 1.73)
To convert kW to Watts multiply kW by 1000
2.4 KW AND TEMPERATURE RISE
The following formula may be used to determine the approximate total kW required when the
CFM (air volume) and desired temperature rise are known:
kW = CFM x rT
3150
2.5 DUCT HEATER TEMPERATURE RISE
The following formula may be used to determine the approximate temperature rise of a duct
heater when the kW and CFM are known:
rT = KW x 3150
CFM
2.6 DETERMINING MAXIMUM HEATER KW
MAXIMUM WATTS PER SQ. IN. OF DUCT AREA
Duct width (inches) x duct height (inches) = duct watts total sq. in.
w
Max W = X x duct area in 2
in 2

w
For EK, X = 208.33
in 2

MAXIMUM KW FOR SQ. FT. OF DUCT AREA
Duct width (feet) x duct height (feet) = duct area total ft 2
Max W = X kW x duct area ft 2
ft 2
For EK, X = 30 kW
ft 2

14 1.800.627.4499
 SYSTEM REQUIREMENTS
EK-Series Electric Duct Heater ACCESSORY

2.7 MINIMUM AIR VELOCITIES

The minimum uniform airflow in a duct heater is directly related to the inlet air temperature.
Consideration must be given to both airflow across the heater and inlet air temperature, (shown
below).
To calculate the kilowatts per sq. ft. of duct area, divide the total kilowatts required by the duct
area.
EXAMPLE: Duct Size = 2ft. x 3ft.
Total kilowatts = 20
KW/Sq. Ft. = 20 = 3.333
6

If the air handler equipment is expressed in FPM then a direct cross reference can be made by
comparing the temperature of the air (as it enters the Duct Heater) to the KW rating on the chart
of rated velocity.
a. D
 raw a line horizontally from the KW/Sq. Ft. required to the inlet air temperature being used.
b. From this point of intersection on the Inlet Air Curve, draw a line down vertically to establish
the air velocity. NOTE: Minimum
c. T he velocity should never be lower than the velocity as determined from the chart. In cases airflow must be
where this is not true, the velocity must be increased or the KW required must be reduced. maintained at any
point over the face
In cases where the air handling equipment is expressed in CFM then convert to FPM by dividing of the heater.
the CFM by the duct area.
EXAMPLE: FPM = CFM
Duct Area

NOTE: Observe at
least one complete
heating cycle to
ensure that cycling
of the safety limit controls
does not occur before
leaving the installation.

FIGURE 2.7.0 FPM VS KW/ FT 2 CHART

1.800.627.4499 15
 PLACEMENT
ACCESSORY EK-Series Electric Duct Heater

3.0 HEATER PLACEMENT

3.1 GENERAL INC.

A duct heater must be

500 GOULD installedCOOKEVILLE,
DRIVE according TN to the
38506 installation instructions, wiring diagram and
labeling supplied with the heater.PHONE (931)432-4141
FAX (931)432-4140

Listed below are ELECTRIC

some importantDUCTitems HEATER
when installing an electric duct heater:
TROUBLESHOOTING GUIDE
1. Never operate a duct
NOTE: An airflow heater without airflow. The EXAMPLE:
INC. IF 780 fpm IS REQUIRED
A DUCT HEATER
switch onlyMUST BE INSTALLED
proves ACCORDING
heater must always be DRIVE
TO THE INSTALLATION INSTRUCTIONS,
that airflow exists WIRING
500 GOULD COOKEVILLE, TN 38506 780 fpm
INC.
CORRECT
interlocked withFAX
the(931)432-4140
fan.
500 GOULD DRIVE COOKEVILLE,
PHONE TN 38506
(931)432-4141 780 fpm MIN. AIRFLOW AND EVEN AIR
DIAGRAM(aAND LABELING
differential in SUPPLIED WITH THE FAX (931)432-4140 PHONE (931)432-4141
This may be accomplished
ELECTRIC DUCT HEATER DISTRIBUTION ARE PRESENT
HEATER.
static pressure), not that ELECTRIC DUCT HEATER 780 fpm
by either an airflow TROUBLESHOOTING
switch
TROUBLESHOOTING GUIDE GUIDE
the minimum air velocities or fan interlock relay.
Listed below are some important
and proper air distribution items when installing EXAMPLE: IF 780 fpmfpm IS REQUIRED
EXAMPLE:
EXAMPLE:IFIF780 ISREQUIRED
REQUIRED
a electric duct heater: 2. NBE
ever operate heater 780 fpm IS
for the ductAheater
DUCT exist.
HEATER MUST
A DUCT HEATER INSTALLED
MUST ACCORDING
BE INSTALLED ACCORDING 780780fpm
780 fpm
fpm INCORRECT
CORRECT
CORRECT
TO THE INSTALLATION INSTRUCTIONS,
TO THE INSTALLATION
without achievingWIRING
INSTRUCTIONS, WIRING
at least 780 fpm
780780
fpmfpm MIN.
MIN. AIRFLOW ANDAND
AIRFLOW EVEN
AND AIR
EVENAIRAIR
DIAGRAMDIAGRAM
1. NEVER OPERATE AAND
DUCT AND LABELING
LABELING theSUPPLIED
HEATER SUPPLIED
WITHOUT
minimum WITHWITH
airflowTHE THE MIN. AIRFLOW EVEN
DISTRIBUTION ARE PRESENT
HEATER. 780 fpm DISTRIBUTION ARE
DISTRIBUTION AREPRESENT
NOT PRESENT
AIRFLOW. HEATER. 500780
fpmfpm
required. Always refer to
The heater must always be interlocked
Listed below arethe
some with items
important
installation the when installing
instructions
Listed
NOTE: below
Allbe
figures are some
a electric important
duct heater: items when installing EXAMPLE: IF 780 fpm IS REQUIRED

fan. This may

a electric accomplished
duct heater: and bytheeither an airflow
nameplate label to
EXAMPLE: IF 780 fpm IS REQUIRED
EXAMPLE: IF 780 fpm780
IS fpm INCORRECT
REQUIRED
are showing a
switch or fan interlock top relay.
780 fpm
780 fpm INCORRECT
MIN. AIRFLOW AND EVEN AIR
1. NEVER determine
OPERATE A DUCTyour minimum
HEATER WITHOUT 470 fpm
view1.ofNEVER
a horizontal
OPERATE
AIRFLOW.A DUCT HEATER WITHOUT
air velocities based on
780 fpm
500 fpm
470500
fpm
INCORRECT
DISTRIBUTION AREAND
MIN. AIRFLOW PRESENT
NOT EVEN AIR
DISTRIBUTION ARE NOT PRESENT
duct.
2. NEVER OPERATE HEATER
AIRFLOW. The heater must alwaysACHIEVING
WITHOUT be interlocked with the fpm
MIN. AIRFLOW IS NOT PRESENT
TheMINIMUM fan. This may
heater mustAIRFLOW your
be inlet
always be interlockedair
accomplished temperature.
bywith
either an airflow
the EXAMPLE: IF470 fpmIS REQUIRED
AT LEAST THE REQUIRED. 780 fpm

fan. This switch

may be or fan Ifinterlock
accomplished relay.
the minimum airflow
by either an airflow 470 fpm
Always refer to the installation instructions and EXAMPLE: IF 780 fpm IS REQUIRED
INCORRECT
switch 2.
the nameplate label
or NEVER
fan interlock
to determine
requirements
OPERATE
relay.
your
HEATERminimum
are not ACHIEVING
WITHOUT
470 fpmFIG.
470 fpm
1
INCORRECT
MIN. AIRFLOW IS NOT PRESENT

air velocities AT LEAST THE

basedOPERATE
on your inlet present
MINIMUM the heater
AIRFLOW
airinstallation
temperature. will
REQUIRED. FIGURE 3.1.0 470
470 fpm
PLACEMENT:MINIMUM
fpm AIRFLOWS
2. NEVER Always referHEATER
to the WITHOUTinstructions
ACHIEVING MIN. AIRFLOW IS NOT PRESENT
If the minimum airflow
AT LEAST THE
the MINIMUM
nameplate
not
requirements function
toare
labelAIRFLOW
properly
notREQUIRED.
determine
and and
your minimum
470 fpm FIG. 1

present the heater

Always willair not
refer to the safely.
function
installation
velocities (see
based properly
on your Figure
and
instructions
inlet 3.1.0)
and
air temperature. 24" MIN.
DUCT
FIG. 1
If the minimum
the nameplate airflow requirements
label to determine are not
your minimum
safely. (see fig. 1) present 3.heater
the Never willoperate the properly
not function heater and 24" MIN.
air velocities based on your inlet air temperature. DUCT

If the minimum airflowwith

safely. (see fig. 1) uneven airflow.
requirements are not
3. NEVER OPERATE THE HEATERThe WITH UNEVEN
minimum airflow 24" MIN.
present3.the heater
NEVER will notTHE
OPERATE function
HEATER properly and
WITH UNEVEN DUCT
AIRFLOW. safely. (see fig. 1) requirements must be
AIRFLOW.
The minimum airflowThe requirements
minimum present must
airflow bepoints
at all
requirements over
must be
present at3.allNEVER
pointsOPERATE
over the
present heater
at THE
all points face.
HEATER WITH
over the UNEVEN
heater face.
the heater face. (see
(see fig. 1) AIRFLOW.(see fig. 1) HEATER
The minimum airflow Figure 3.1.0) must be FIG. 2
FIG. 2 HEATER
requirements HEAT PUMP OR
4. THE AIR MUST BE FILTERED. DUCT
present at all points
4. over the must
heaterbeface. HEAT PUMP
FIGURE ORPLACEMENT:
3.1.1 ELBOW MINIMUM
DUCTREQUIREMENT
4. THE AIR MUST BE FILTERED.
The incomingTair
hemust
air filtered.
be free from all debris,
AIR CONDITIONER
48" MIN.
(see fig. 1) AIR CONDITIONER
The incoming air must be free The
fromincoming
all debris,
combustible particles, and hazardous vapors.
air must 48"
FIG.MIN.
2 HEATER

combustible particles,
4. THE AIR and
5. MUST
hazardous
be
BELOCATE
ALWAYS free
FILTERED. vapors.
THE HEATERdebris,
from all AT LEAST 24"
HEAT PUMP OR DUCT
AIR CONDITIONER
The incoming
FROMair combustible
ANmust be OR
ELBOW fromparticles,
freeTURN. and
all debris, 48" MIN.
5. ALWAYS LOCATE THE
combustible HEATER
(see particles, AT hazardous
and
fig. 2) hazardous LEAST 24"
vapors.
vapors.
FROM AN ELBOW OR TURN.
6. ALWAYS
LOCATELOCATE
5.THE THElocate
A lways HEATER
AT theAT LEAST
heater 48"
24" at
HEATER
(see fig. 2)5. ALWAYS FROM HEATER LEAST FIG. 3
AN HEAT PUMP OR CENTRAL AIR
FROM AN ELBOW OR TURN.
least 24" from an elbow or 48" MIN. 48" MIN.
CONDITIONER.
(see fig. 2)
(see fig. 3) turn. (See Figure 3.1.1)
6. ALWAYS LOCATE THE HEATER AT LEAST 48" FIG. 3 HEATER
FROM AN6.HEAT PUMP
ALWAYS OR CENTRAL
LOCATE
7. ALWAYS 6.THE
A lways
LOCATE HEATERAIR
THElocate
AT the
HEATER heater
LEAST
AT 48" 48"
LEAST FIG. 3 HEATER
48" MIN. 48" MIN.
CONDITIONER. FROM ANFROM
HEATANY
PUMP OR
CANVAS CENTRALfromAIR
at least 48" CONNECTOR
DUCT an ERV,OR
TRANSITION SECTION FOR CHANGE IN DUCT
(see fig. 3) CONDITIONER. FIGURE 3.1.248" MIN.
PLACEMENT: 48" MIN.
LOCATION REQUIREMENTS
heat pump or central air
(see fig. 3)SIZE.
DUCT
HEATER
conditioner. (See Figure
(see fig. 4) CORRECT
7. ALWAYS LOCATE THE HEATER AT LEAST 48"
7. ALWAYS LOCATE 3.1.2)
THE HEATER AT LEAST 48"
FROM ANY CANVAS DUCT CONNECTOR OR
8. ALWAYS LOCATE THE HEATER AT LEAST 48"
FROM ANY CANVAS DUCT CONNECTOR OR
DOWNSTREAM FROM AN AIR HANDLER.
TRANSITIONTRANSITION
SECTION FOR
SECTIONCHANGE
(see fig. 5) FOR IN DUCT
CHANGE IN DUCT
SIZE. SIZE. DUCTDUCT
DUCT HEATER
HEATER
(see fig. 4) (see fig.
9. 4)ALWAYS LOCATE THE HEATER AT LEAST 48" CORRECT
CORRECT HEATER
UPSTREAM FROM AN HUMIDIFIER. INCORRECT
(see fig. 6)
8. ALWAYS 8. ALWAYS
LOCATE THELOCATE THE HEATER
HEATER AT 48"
AT LEAST LEAST 48" FIG. 4

DOWNSTREAM FROM AN AIR HANDLER. NOTE: ALL FIGURES ARE SHOWING A TOP
DOWNSTREAM FROM AN AIR HANDLER. VIEW OF A HORZONTIAL DUCT. PAGE 1 OF 2
(see fig. 5)
(see fig. 5) DUCT
9. ALWAYS LOCATE THE HEATER AT LEAST 48" DUCT
HEATER
169. 1.800.627.4499
ALWAYS LOCATE THEFROM
UPSTREAM HEATER AT LEAST 48"
AN HUMIDIFIER. INCORRECT HEATER
UPSTREAM (see FROM
fig.AN
6) HUMIDIFIER. INCORRECT
FIG. 4
 present at all points over the heater face.
(see fig. 1) HEATER
FIG. 2

THE AIR MUST BE FILTERED. HEAT PUMP OR

AIR CONDITIONER
DUCT
PLACEMENT
The incoming air must be free from all debris, 48" MIN.
combustible particles, and hazardous vapors.
EK-Series Electric Duct Heater ACCESSORY
ALWAYS LOCATE THE HEATER AT LEAST 24"
FROM AN ELBOW OR TURN.
(see fig. 2)

ALWAYS LOCATE THE HEATER AT LEAST 48" FIG. 3 HEATER

7. A lways locate the heater
FROM AN HEAT PUMP OR CENTRAL AIR
CONDITIONER. at least 48" from any 48" MIN. 48" MIN.

(see fig. 3) canvas duct connector

or transition section
ALWAYS LOCATE THE HEATER AT LEAST 48"
for DUCT
FROM ANY CANVAS change in duct size.OR
CONNECTOR
If connecting
TRANSITION SECTION to round
FOR CHANGE IN DUCT
SIZE. duct, install heater in a DUCT
HEATER
(see fig. 4) CORRECT
rectangular duct section.
ALWAYS LOCATEUse THEround-to-rectangular
HEATER AT LEAST 48"
DOWNSTREAM FROM pyramidal
AN AIRtransitions
HANDLER.to
(see fig. 5) connect round duct to
DUCT
rectangular duct. Always
ALWAYS LOCATE THE HEATER AT LEAST 48"
UPSTREAM FROM locate the heater at least
AN HUMIDIFIER. INCORRECT
HEATER

(see fig. 6) 48" from any transition FIG. 4

section for change in duct FIGURE
NOTE: 3.1.3 PLACEMENT:
ALL FIGURES TRANSITION
ARE SHOWING A TOP REQUIREMENTS
VIEW OF A HORZONTIAL DUCT. PAGE 1 OF 2
size. Follow installation
guidelines given in manual
0. ALWAYS LOCATE THE HEATER AT LEAST 48"
AIR HANDLER

48" MIN.
DOWNSTREAM and FROMin AN
accordance with
AIR FILTER. DUCT
AIR HANDLER
(see fig. 7)LOCATE
0. ALWAYS SMACNA guidelines
THE HEATER (see 48"
AT LEAST
DUCT 48" MIN.
DOWNSTREAM Figure
FROM AN 3.1.3)
AIR FILTER.
1. NEVER INSTALL A STANDARD HEATER INTO A
(see fig. 7)
AIR HANDLER
0. ALWAYS LOCATE THE HEATER AT LEAST 48"
DUCT WITH AN INTERNAL
8.FROMA lways OBSTRUCTION.
ANlocate the heater DUCT 48" MIN.
DOWNSTREAM AIR FILTER.
Due
1.(see
NEVER to the fact that
INSTALL an obstruction
A least
STANDARD can block
HEATER INTO A
fig. 7)
airflow at theAN at
temperature 48" downstream
DUCT WITH INTERNALlimit controls and
OBSTRUCTION.
element terminations.
Due to the fact that from an
If air
this
an obstruction handler.
situation (See
exist,
can block it
1. NEVER
can be INSTALL
corrected AbySTANDARD
using HEATER
a heater with INTO
a A HEATER
airflow
DUCT at
WITH the Figure
temperature
AN INTERNAL 3.1.4)
limit controls
OBSTRUCTION. and FIG. 5
recessed
element control
terminations. box and If reduced
this situationwrapper
exist, size.
it
Due
Thisto the fact that an obstruction can block
can
airflow besituation
atcorrected
thefig.
9.is Acommon
lways
by
temperature using locate
with
a heater
limit
the
controls
heater
internally
withand
at
ainsulated
FIGURE 3.1.4 PLACEMENT: DOWNSTREAMHUMIDIFIER
HEATER REQUIREMENTS
ducts. (see 8)
controlleast
FIG. 5
If48" upstream fromitsize. 48" MIN.
recessed
element terminations. box and thisreduced
situation wrapper
exist, DUCT

Thisbesituation is an common awith

humidifier. internally
(See a insulated
HEATER HUMIDIFIER
2.can
NEVER corrected
ducts. (see INSULATE
fig. 8)box
by using
THE EXTERIORheater OF Figure
with THE FIG. 5
recessed control
CONTROL BOX.3.1.5) and reduced wrapper size. DUCT 48" MIN.

This
The situation
control is common
box must be with internally
completely insulated
accessible
HUMIDIFIER
2.ducts.
NEVER (seeINSULATE
fig. 8) ATHE EXTERIOR OF THE
and located
CONTROL
10.
where
BOX.
lways
ventilation locate canthe heater at
be provided DUCT 48" MIN.

all times.
The control (see fig.
box must at9)least
be 48" downstream
completely
2. NEVER INSULATE THE EXTERIOR OFaccessible
THE
and located wherefrom an air can
ventilation filter.
be (See
provided at
3.CONTROL
NEVER
all times.
BOX.
INSTALL
(see fig. A9)
HEATER NEAR A DOUBLE HEATER
The control
BLOWER OUTLET. box must be
Figure completely
3.1.6) accessible
FIG. 6
and located where ventilation can be provided at
A heaterINSTALL
3.all
NEVER must be Ainstalled farNEAR
enough away from
a times. blower
double (see fig.outlet 9)HEATERthat even and proper
A DOUBLE HEATER AIR FILTER
BLOWER OUTLET. FIG.MIN.
48" 6
airflow
A heater ismust
present or separate
beAinstalled duct heaters DUCT
3. NEVER INSTALL HEATERfar NEARenough away from
A DOUBLE FIGURE 3.1.5 PLACEMENT: HUMIDIFIER AIR
REQUIREMENTS
placed
a double in blower
the duct runouts
outlet that of each
even andblower.
proper(all
HEATER FILTER
BLOWER OUTLET. FIG. 6
installation must conform withduct the heaters
heater 48" MIN.
Aairflow
heaterismust present or separate
be installed far enough away from DUCT
installation instructions.) (see fig. 10)
aplaced
doubleinblower the duct runouts of each andblower.
proper(all
AIR FILTER
outlet that even
installation must or conform with theheaters
heater 48" MIN.
4.airflow is INSTALL
present A separate
HEATER duct
DUCT
NEVER
installation LESS THAN 48"
placed in theinstructions.)
duct runouts (see of each fig. blower.
10) (all
FROM ANY FAN.
installation must conform with the heater
Mounting
4.installation
NEVER a heaterAany
INSTALL HEATERcloserLESS than THAN
48" to 48"
a fan
will result instructions.) (see fig. 10)
ANYinFAN. uneven airflow. HEATER
FROM FIG. 7
Mounting
4. NEVER INSTALLa heater any closer
A HEATER LESSthanTHAN48" to48"
a fan
5. ORDER
will result THE uneven
HEATERairflow. WITH THE FACTORY
ANYin
DUCT W/ INTERNAL
HEATER INSULATION
FROM FAN.
INSTALLED LINEAR TEMPERATURE LIMIT FIG. 7
Mounting a heater any closer than 48" to a fan
CONTROL
5. will
ORDER IFHEATER
THE HEATER WITH WIDTH > 72".
resultTHE in uneven airflow. THE FACTORY DUCT W/ INTERNAL
HEATER INSULATION
INSTALLED LINEAR TEMPERATURE LIMIT FIG. 7
6. NEVER
CONTROL USE ALUMINUM CONDUCTORS.
5. ORDER THEIFHEATERTHE HEATER WITH THE WIDTH > 72".
FACTORY FIGURE 3.1.6
DUCTPLACEMENT:
W/ INTERNALAIR FILTER REQUIREMENTS
INSULATION
Use copper conductors only for all incoming
INSTALLED
wiring. LINEAR TEMPERATURE LIMIT
6. CONTROL
NEVER USE ALUMINUM
IF THE HEATER CONDUCTORS.
WIDTH > 72".
Use copper conductors only for all incoming CORRECT
7. NEVER INSTALL A STANDARD HEATER INCORRECT
wiring.USE
6. NEVER
OUTDOORSALUMINUM CONDUCTORS. FIG. 8
WITHOUT MAKING SPECIAL
Use copper
PROVISIONS conductors
TO PROTECT only THE for all incoming
HEATER
7. wiring.
NEVER INSTALL A STANDARD HEATER CORRECT INCORRECT
DUCT W/ EXTERNAL INSULATION
AND CONTROL BOX
OUTDOORS WITHOUT MAKING SPECIAL FROM THE ELEMENTS. FIG. 8

PROVISIONS
7. NEVER INSTALL TOAPROTECT
STANDARD THE HEATER
HEATER CORRECTDUCT W/ EXTERNAL INSULATION
INCORRECT
8. NEVER
AND CONTROL BUNDLE,BOX TIE OR FROM WRAP THE POWER
ELEMENTS. WIRING. FIG. 8
OUTDOORS WITHOUT MAKING
The wire could overheat or the insulation could SPECIAL
PROVISIONS
breakdown. TO PROTECT THE HEATER DUCT W/ EXTERNAL INSULATION
8. AND
NEVER CONTROLBUNDLE, BOX TIEFROM
OR WRAP THE POWERELEMENTS. WIRING.
The wire could overheat or the insulation could
9. NEVER
breakdown. USE A DIFFERENT VOLTAGE AND/OR CORRECT
8. NEVER INCORRECT
PHASEBUNDLE, THAN WHAT TIE OR WRAP POWER
IS LISTED ON THEWIRING.
HEATER
The wire couldLABEL.
NAMEPLATE overheat or the insulation could FIG. 9
9. breakdown.
NEVER USE A DIFFERENT VOLTAGE AND/OR CORRECT
The ductTHAN heater is to IS
be LISTED
used only INCORRECT
PHASE WHAT ONatTHE
the HEATER
voltage
and phase that
NAMEPLATE is listed on the nameplate label. FIG. 9 1.800.627.4499 17
9. NEVER USE A LABEL. DIFFERENT VOLTAGE AND/OR CORRECT
The duct heater is toISbeLISTED
used only at theHEATER
voltage INCORRECT
PHASE
Note: THAN
An airflow WHAT
switch only proves ON THE
that airflow exist FIG. 9
 A heater must be installed far enough away from
13. NEVER INSTALL A HEATER NEAR A DOUBLE AIR FILTER
a double blower outlet that even and proper HEATER
13. NEVER
BLOWER INSTALLOUTLET.A HEATER NEAR A DOUBLE
airflow is present or separate duct heaters DUCT
48"
FIG.MIN.
6
HEATER
A heaterOUTLET.
BLOWER must be installed far enough away from
PLACEMENT
placed
a double
A heater
in
must
the duct
blower
runouts of each blower. (all
outlet that
be installed even and proper
FIG. 6
AIR FILTER
installation must conformfar withenough
the heateraway from
48" MIN. AIR FILTER
airflow blower
a double is present or separate
outlet that(see
even duct
and heaters
10)proper
DUCT
installation instructions.) fig.
ACCESSORY
placed
airflow is in the duct
present runouts
EK-Series
or separate ofElectric
eachheaters
duct blower.
Duct(all Heater DUCT
48" MIN.

installation
placed in the must runouts
duct conformof with
eachtheblower.
heater (all
14. NEVER INSTALL A HEATER LESS THAN 48"
installation
installation instructions.)
must conform with (see the
fig. heater
10)
FROM ANY FAN.
installation
Mountinginstructions.)
a heater any closer (see fig.than 10)48" to a fan
14. NEVER INSTALL A HEATER LESS THAN 48"
will result in uneven airflow. HEATER
FROM ANY FAN.
14. NEVER INSTALL A 11.HEATER
N
 ever LESS aTHAN
install 48"
standard
FIG. 7
Mounting a heater any closer than 48" to a fan
15. ORDER
FROM ANY THE HEATER WITH THE FACTORY
FAN. DUCT W/ INTERNAL INSULATION
will result in unevenheater airflow.into a duct with HEATER
INSTALLED
Mounting LINEAR
a heater anyTEMPERATURE
closer than 48"LIMIT to a fan FIG. 7
CONTROL
will result in uneven an internal
IF THE HEATER
airflow. WIDTH obstruction.
> 72". HEATER
15. ORDER THE HEATER WITH THE FACTORY DUCT W/ INTERNAL
FIG. INSULATION
INSTALLED LINEARDue to the fact that an 7
TEMPERATURE LIMIT
15.16. NEVER
ORDER
CONTROL THEUSE ALUMINUM
HEATER WITH CONDUCTORS.
obstruction
IF THE HEATER THE
WIDTH FACTORY
can> 72".
block DUCT W/ INTERNAL INSULATION
Use copperLINEAR
INSTALLED conductors only for all incoming
TEMPERATURE LIMIT
wiring. IF THE HEATER airflow at the temperature
CONTROL
16. NEVER USE ALUMINUM WIDTH > 72".
limit CONDUCTORS.
controls and element
Use copper conductors only for all incoming CORRECT INCORRECT
17. NEVER INSTALL A STANDARD terminations. HEATER
If this
16. NEVER
wiring. USE ALUMINUM CONDUCTORS. FIG. 8
OUTDOORS WITHOUT MAKING
situation SPECIAL
exists, it can
Use copper conductors only for all incoming
PROVISIONS TO PROTECT THE HEATER 3.1.7DUCT
CORRECT
FIGURE W/ EXTERNAL
PLACEMENT: INSULATION
OBSTRUCTION REQUIREMENTS
wiring.
17. NEVER INSTALL A STANDARD be corrected by
HEATER using a INCORRECT
AND CONTROL BOX FROM THE ELEMENTS. FIG. 8
OUTDOORS WITHOUT heaterMAKINGwith SPECIAL
a recessed
17.18. PROVISIONS
NEVER INSTALL TO A PROTECT
STANDARD THE HEATER CORRECT INCORRECT
NEVER
AND CONTROL
BUNDLE, control
TIE OR WRAP
BOX MAKING
FROM THE
boxHEATER
and
POWER reduced
ELEMENTS.
WIRING. DUCT W/ EXTERNAL INSULATION
FIG. 8
OUTDOORS WITHOUT
The wire could overheat or the SPECIAL
insulation could
PROVISIONS wrapper size. This
breakdown. TO PROTECT THE HEATER DUCT W/ EXTERNAL INSULATION
18. NEVER BUNDLE, situation
TIE
AND CONTROL BOX FROM THE ELEMENTS.OR WRAP is common
POWER with
WIRING.
The wire could overheat or theinsulated
internally insulationducts.could
19. NEVER USE A DIFFERENT VOLTAGE AND/OR CORRECT
breakdown. INCORRECT
18. NEVER
PHASE BUNDLE,
THAN WHAT TIE (see
OR WRAP
FigurePOWER
IS LISTED 3.1.7)
ON THE WIRING.
HEATER FIG. 9
The wire could overheat
NAMEPLATE LABEL. or the insulation could
19. NEVER USE A DIFFERENT VOLTAGE AND/OR
The duct heater 12.
breakdown. is toNbeever insulate
used only atthe theexterior
voltage CORRECT INCORRECT
PHASE THAN
thatWHAT IS LISTED ON THE HEATER
and phase
NAMEPLATE LABEL.
of
is listed the
on control box.
the nameplate Thelabel. FIG. 9

19. NEVER
The ductUSEheater
A DIFFERENT
is tocontrol
be usedVOLTAGE
box
only must AND/OR
at thebevoltage CORRECT
Note: An airflow switch IS only proves that airflow exist FIGURE INCORRECT
3.1.8 PLACEMENT: CONTROL BOX REQUIREMENTS
PHASE THANthat
and phase WHAT LISTED
completely
is listed ON THE
accessible
on the nameplate HEATERand
label. FIG. 9
(a differential
NAMEPLATE in static
LABEL. pressure), not that the
The minimum
duct air is
heater
located
velocities
to be andwhere
used proper
only
ventilation
air voltage
at the
Note: An airflow switch only proves that airflow exist
distribution
and (a
phase that is thecan
forlisted duct
on betheprovided
heater exist.at all
nameplate label.
differential in static pressure), not that the INCORRECT
minimum air velocities times.and (see Figure
proper air 3.1.8)
FIG. 10
NOTE: ALL FIGURES ARE SHOWING A TOP
Note: Andistribution
airflow switch for theonly proves
heaterthat airflow exist PAGE 2 OF 2
(a differential in13. Nduct
static ever installexist.
pressure), anot
heater
that the
VIEW OF A HORZONTIAL DUCT.
FIG. 10
INCORRECT
minimum air velocities nearanda double
properblower
air NOTE: ALL FIGURES ARE SHOWING A TOP
PAGE 2 OF 2
distribution for the duct outlet. A heater
heater exist.must VIEW OF A HORZONTIAL DUCT.
INCORRECT
be installed far enough FIG. 10
NOTE: ALL FIGURES ARE SHOWING A TOP
away from a double VIEW OF A HORZONTIAL DUCT. PAGE 2 OF 2
blower outlet that even FIGURE 3.1.9 PLACEMENT: DOUBLE BLOWER REQUIREMENTS
and proper airflow is
present or separate duct
heaters placed in the duct 15.Never use aluminum 17. Never bundle, tie or
runouts of each blower. conductors. Use copper wrap power wiring. The
(all installation must conductors only for all wire could overheat or the
conform with the heater incoming wiring. insulation could breakdown.
installation instructions.) 16. N
 ever install a standard 18. Never use a different
(see Figure 3.1.9) heater outdoors without voltage and/or phase
14. Never install a heater making special provisions than what is listed on the
less than 48" from any to protect the heater heater nameplate label.
fan. Mounting a heater and control box from the The duct heater is to be
any closer than 48" to a elements. used only at the voltage and
fan will result in uneven phase that is listed on the
airflow. nameplate label.

18 1.800.627.4499
 ELECTRICAL DATA
EK-Series Electric Duct Heater ACCESSORY

4.0 ELECTRICAL DATA

4.1 TYPICAL CONTACTOR POWER CIRCUITRY
(Only power circuit shown, safety devices etc., omitted)

DISCONNECTING TYPE: DISCONNECTING TYPE:

SINGLE PHASE CONTACTOR

SINGLE PHASE CONTACTOR
SINGLE SINGLE HEATING
HEATING
PHASE PHASE ELEMENT
ELEMENT
SUPPLY SUPPLY
TWO LINE BREAK
SINGLE LINE BREAK
Heating power is completely disconnected
This type would be disconnecting for
by breaking both sides of the power
120V and 277V, providing the contactor
source. All ungrounded power conductors
opens the ungrounded line.
are disconnected. CONTACTOR
THREE PHASE
Heating elements, namely those used in SINGLE
three phase, balanced, configurations PHASE
are factory wired, as manufacturers SUPPLY
WYE DELTA
standard in two basic configurations
All ungrounded conductors disconnected.
delta or WYE.
Both WYE and Delta configurations shown.

FIGURE 4.1.0 TYPICAL CONTACTOR POWER CIRCUITRY

4.2 HEATING ELEMENT WIRING CONFIGURATIONS AND PROPERTIES

SINGLE PHASE THREE PHASE

L1
l L1 l L1
L1
480V l L2
L2
LINE 480V
HEATING
VOLTAGE ELEMENT(S) 480V
480V
l L2 480V
L2
480V
L3
l L3 l L3
L3
480V for illustration only

Element Voltage = Line Voltage THREE WIRE DELTA CONNECTION THREE WIRE WYE CONNECTION

1. Element Voltage = Line Voltage 1. Element Voltage = Line Voltage

2. Phase Currents In = l L1 = l L2 = l L3 1.73

3. Voltage measured between any two 2. Phase Currents In = l L1 = l L2 = l L3

power legs (L1 to L2 etc.) should be
3. Voltage measured between any
equal to the three phase line
two power legs (L1 to L2 etc.)
voltage.
should be equal to the three phase
line voltage.

FIGURE 4.2.0 HEATING ELEMENT WIRING PROPERTIES

1.800.627.4499 19
 ELECTRICAL DATA
ACCESSORY EK-Series Electric Duct Heater

4.3 HEATER WIRING SCHEMATICS

NOTE: See low

voltage control
connections, pages
23-25, for external
control wiring.

FIGURE 4.3.0 SINGLE PHASE ON-OFF HEATER WIRING

NOTE: See low

voltage control
connections, pages
23-25, for external
control wiring.

FIGURE 4.3.1 SINGLE PHASE SCR HEATER WIRING

20 1.800.627.4499
 ELECTRICAL DATA
EK-Series Electric Duct Heater ACCESSORY

NOTE: See low

voltage control
connections, pages
23-25, for external
control wiring.

FIGURE 4.3.2 THREE PHASE ON-OFF HEATER WIRING

NOTE: See low

voltage control
connections, pages
23-25, for external
control wiring.

FIGURE 4.3.3 THREE PHASE SCR HEATER WIRING

1.800.627.4499 21
 ELECTRICAL DATA
ACCESSORY EK-Series Electric Duct Heater

WARNING
RISK OF FIRE, ELECTRIC SHOCK, OR INJURY. OBSERVE ALL CODES AND THE FOLLOWING:
1. B efore servicing or cleaning the heater, 3. Installation work and electrical wiring
switch power off at disconnect switch must be done by qualified professional(s)
or service panel and lock-out/tag-out to in accordance with all applicable codes,
prevent power from being switched on standards and licensing requirements.
accidentally. More than one disconnect 4. A ny structural alterations necessary for
switch may be required to de-energize installation must comply with all appli-
the equipment for servicing. cable building, health, and safety code
2. T his installation manual shows the requirements.
suggested installation method. Additional 5. This
 heater must be grounded.
measures may be required by local codes
and standards. 6. U
 se the heater only in the manner in-
tended by the manufacturer. If you have
questions, contact the manufacturer.

4.4 LOW VOLTAGE CONTROL SYSTEM

CAUTION
1. Connect only to components intended for use with 24 VAC power.
2. D
 o not undersize the low-voltage wires connected to this device. Observe the wire length and
gauge limits indicated in this manual.
3. Do not overload this unit’s 24 VAC power supply system. Confirm that the power requirements of
devices you connect to this power supply system do not exceed transformer available power.

This heater is provided with a Class II 24 VAC power supply system that operates the unit’s contactor(s).
The 24 VAC Power Supply can also be used to power the externally-installed controls system.
In the event of a short-circuit or overload, the transformer itself is designed to fail safely.
4.4.1 Specifications
u N ominal Output Voltage under load: 24 VAC
u Typical Output Voltage at no load: 29-31V
u Minimum contact rating for connected control device: (50mA (1.2VA))
4.4.2 Limits of Power Output
If limits on wire gauge and length are observed, you may connect control devices that draw
up to 8VA to the provided terminals. More than one device can be connected as long as total
steady-state load does not exceed transformer available power.

OBSERVE THESE LIMITS TO WIRE LENGTH AND GAUGE

in order to ensure reliable operation of the control system.
Wire Gauge #22 #20 #18 #16 #14 #12
Circuit Length 100' 150' 250' 400' 700' 1000'
“Circuit Length” is distance from Heater to Control Device.

22 1.800.627.4499
 ELECTRICAL DATA
EK-Series Electric Duct Heater ACCESSORY

4.5 LOW VOLTAGE CONTROLS CONNECTIONS

These heaters may be ordered with factory-supplied thermostats.
NOTE: Installation details for Electric Duct Heaters equipped with SCR's or Electronic Step Controllers
(Including SCR Vernier Control)
This heater is designed to accept an analog control signal. The heater will need to be supplied with either
a 0(2) to 10 VDC or a 4 to 20 mA signal.

4.5.1 Interface Module Control Signal Wiring Connection Diagram

FIGURE 4.5.0
DUCT HEATER SIGNAL
STAND ALONE INTERFACE MODULE
THERMOSTAT FOR 1 2 3 4 CAUTION
MODULATING CONTROL: This heater will NOT
COMMON
Use this schematic if 24 VAC operate with a standard 24
thermostat requires 24 VAC 0 TO 10 VAC control signal.
VDC OUTPUT
power and is to be powered by
the heater transformer. 2 TO 10 VDC
STAND ALONE THERMOSTAT
CAUTION
FIGURE 4.5.0 STANDALONE THERMOSTAT FOR MODULATING CONTROL Do NOT adjust any dip
switches on the controls
FIGURE 4.5.1
within the heater!
DDC BAS FOR MODULATING DUCT HEATER SIGNAL They are factory set-
CONTROL (2-10VDC): Use INTERFACE MODULE control. Signal is
this schematic if the Building 1 2 3 4 determined by interface
Automation System provides a - module connection.
2-10 Vdc signal to control the +
heater. 2 TO 10 VDC FROM
D.D.C. BUILDING AUTOMATION SYSTEM

FIGURE 4.5.1 DDC BAS FOR MODULATING CONTROL (2-10 VDC)

FIGURE 4.5.2 NOTE: See

DDC BAS FOR MODULATING DUCT HEATER SIGNAL documentation
with thermostat for
CONTROL (4-20 MA): Use INTERFACE MODULE
1 2 3 4 complete
this schematic if the Building
- installation instructions.
Automation System provides a
+
4-20 mA signal to control the
heater. 4 TO 20 mA FROM D.D.C.
BUILDING AUTOMATION SYSTEM

FIGURE 4.5.2 DDC BAS FOR MODULATING CONTROL (4-20 MA)

1.800.627.4499 23
 ELECTRICAL DATA
ACCESSORY EK-Series Electric Duct Heater

4.5.2 Electronic Step Controller or SCR Control

FIGURE 4.5.3

NOTE: See doc- VICONICS

 ROOM VICONICS VT7225 ROOM
THERMOSTAT
DUCT HEATER
SIGNAL INTERFACE
umentation with THERMOSTAT WITHOUT 24 VAC 4 MODULE

thermostat for REMOTE SENSOR FOR COMMON 5

1

complete installation MODULATING CONTROL: 0 TO 10 VDC 9 2

instructions. Use this schematic if a REMOTE SENSOR 13 3

Viconics thermostat without SENSOR COMMON 14 4
remote sensor is used to SUPPLY SENSOR 16
control the heater.

FIELD WIRING:

FIGURE 4.5.3 VICONICS ROOM THERMOSTAT WITHOUT REMOTE SENSOR FOR

MODULATING CONTROL

FIGURE 4.5.4
VICONICS VT7225 ROOM DUCT HEATER
V ICONICS ROOM THERMOSTAT
24 VAC 4
SIGNAL INTERFACE
MODULE

THERMOSTAT WITH VICONICS VT7225COMMON

ROOM 5
1
DUCT HEATER
REMOTE SENSOR FOR THERMOSTAT
0 TO 10 VDC 9 2 INTERFACE
SIGNAL
SENSOR4 13
24 VAC 3MODULE
MODULATING CONTROL: REMOTE
1
SENSOR COMMON 14 4
COMMON 5
Use this schematic if a SUPPLY SENSOR 16
2
Viconics thermostat with 0 TO 10 VDC 9
3
remote sensor is used to REMOTE SENSOR 13
HEATER
ELEMENTS

DUCT
control the heater for return SENSOR COMMON 14 4

air temeprature. SUPPLY SENSOR

AIRFLOW 16

FIELD WIRING:

FIGURE 4.5.4 VICONICS ROOM THERMOSTAT WITH REMOTE SENSOR FOR

F MODULATING CONTROL - RETURN AIR TEMPERATURE

FIGURE 4.5.5
VICONICS VT7225 ROOM DUCT HEATER
V ICONICS ROOM THERMOSTAT SIGNAL INTERFACE
MODULE
24 VAC 4
THERMOSTAT WITH VICONICS VT7225 ROOM
COMMON 5
1
DUCT HEATER
REMOTE SENSOR FOR THERMOSTAT0 TO 10 VDC 9 2 INTERFACE
SIGNAL
MODULE
MODULATING CONTROL: 24 VAC
REMOTE 4
SENSOR 13 3

SENSOR COMMON 14 4 1
Use this schematic if a COMMON 5
SUPPLY SENSOR 16
2
Viconics thermostat with 0 TO 10 VDC 9

remote sensor is used 3

HEATER
REMOTE SENSOR 13 ELEMENTS

DUCT
to control the heater for SENSOR COMMON 14 4

supply air temperature. AIRFLOW

SUPPLY SENSOR 16

FIELD WIRING:
FIELD WIRING:

FIGURE 4.5.5 VICONICS ROOM THERMOSTAT WITH REMOTE SENSOR FOR

MODULATING CONTROL - SUPPLY AIR TEMPERATURE

24 1.800.627.4499
 ELECTRICAL DATA
EK-Series Electric Duct Heater ACCESSORY

4.5.3 Staged Control

FIGURE 4.5.6
SINGLE STAGE VICONICS VT7200 ROOM
DUCT HEATER
TERMINAL

THERMOSTAT WITH THERMOSTAT BLOCK

24V
24 VAC 4
REMOTE SENSOR FOR ON/ COMMON 5
C

OFF CONTROL: Use this

R1
AUX BO 5 6

AUX BO 5 7
R2
NOTE: See doc-
schematic to control a single CLOSE HEAT BO 4 9
umentation with
stage heater.
REMOTE SENSOR 13
SENSOR COMMON 14
HEATER
ELEMENTS thermostat for
DUCT complete installation
THERMOSTAT SETTINGS:
Out1Conf = 4.0
Control Type = On/Off
AIRFLOW instructions.
Seq.Opera = 1
P Band = 10

FIELD WIRING:

FIGURE 4.5.6 SINGLE STAGE THERMOSTAT WITH REMOTE SENSOR FOR ON/OFF CONTROL

FIGURE 4.5.7
2-STAGE THERMOSTAT DUCT HEATER
VICONICS VT7200 ROOM TERMINAL
WITH REMOTE SENSOR THERMOSTAT BLOCK
24V

FOR ON/OFF CONTROL: Use

24 VAC 4
C
COMMON 5

this schematic to control a AUX BO 5 6

R1

R2
7
2-stage heater.
AUX BO 5

CLOSE HEAT BO 4 9
REMOTE SENSOR 13
HEATER
SENSOR COMMON 14 ELEMENTS

DUCT
THERMOSTAT SETTINGS:
Out1Conf = 4.0 AIRFLOW
Control Type = On/Off
Seq.Opera = 3
P Band = 10

FIELD WIRING:

FIGURE 4.5.7 2-STAGE THERMOSTAT WITH REMOTE SENSOR FOR ON/OFF CONTROL

1.800.627.4499 25
 INATALLATION
ACCESSORY EK-Series Electric Duct Heater

5.0 INSTALLATION
5.1 PLACEMENT OF THE ELECTRIC DUCT HEATER
u T he information and instructions in this sheet apply to Duct Heater models for zero clearance
installation in ducts.
u T he Duct Heaters are approved for use Post ERVs with heat pumps, air conditioners, or other
CAUTION forced air systems. They may be controlled by contactors, relays, sequencers or solid state
The air duct should be devices.
installed in accordance u T he Duct Heaters are prewired, have voltage ratings to 600 volts, both single phase and three
with the Standards of the phase.
National Fire Protection
Agency for the Installa-
u T he Duct Heaters are furnished with integral controls.
tion of Air-Conditioning
and Ventilating Systems 5.2 HEATER INSPECTION
(Pamphlet No. 90A) and Inspect heater for any possible shipping damage. Check all insulators for breakage and inspect
Warm-Air Heating and heater element wire for any deformation that could cause a short circuit or ground. Make sure
Air-Conditioning Systems all fasteners are tight.
(Pamphlet No. 90B).
Electrical connections such as pressure terminals should be checked for tightness.
INSTALLATION
CAUTION
For safe operation and best performance, the following installation procedures must be adhered
Do not “Bank” heaters
to:
(side by side). If greater
capacity is required, pro- Heaters may be installed in the sides of either horizontal or vertical ducts but never in the top or
portion smaller heaters in bottom of a horizontal duct. Vertical up and down airflow available in EK series.
separate runouts. Install a heater a minimum of (4) feet from heat pumps or central air conditioners.
At least 4 feet downstream from an air handler.
CAUTION At least 2 feet either side of an elbow or turn.
Heater control boxes must
be completely accessible At least 4 feet from any canvas duct connector or transition section for change in duct size.
and located to provide At least 4 feet downstream from an air filter.
ventilation at all times. At least 4 feet upstream from a humidifier.
DISCLAIMER
Model EK duct heaters offered by RenewAire are not to be installed in, on, or directly attached
to any equipment and further must be installed according to the installation instructions shipped
with each and every duct heater.
Refer to Page 15 for duct and air velocity requirements.

26 1.800.627.4499
 IIN
NSSTTAALLLLAATTIIO
ONN M
MAANNUUAALL
INSTALLATION
TU
T UTTC
COOD
DUUC
CTT H
HEEAATTEERRSS
The information and instructions in this sheet apply to Duct Heater
The information and instructions in this sheet apply to Duct Heater
EK-Series Electric Duct Heater ACCESSORY
models for zero clearance installation in ducts.
models for zero clearance installation in ducts.
The
The Duct Heaters are
Duct Heaters are approved
approved forfor use
use with
with heat
heatpumps,
pumps,air
air
conditioners, or other
conditioners, or other forced
forced air
air systems.
systems. They
Theymay
maybebecontrolled
controlledby
by
contactors, relays, sequencers
contactors, relays, sequencers or or solid
solid state
state devices.
devices.

The
The Duct Heaters are
Duct Heaters are prewired,
prewired, have
have voltage
voltage ratings
ratingsto
to600
600volts,
volts,both
both

5.3single
DUCT
single phase
INSTALLATION
and three
phase and three phase.
phase.

The Duct Heaters are furnished with integral controls, except for the DD
To &The
& DHD
Duct Heaters are furnished with integral controls, except for the DD
install a slip-in
series,
DHD series, which are
which heater
are furnished FIGURE
furnished with
with aa separate
separate 5.3.0, cutforforan opening, as required in the side of the duct. Slide
controlpanel
control panel
remote mounting.
heater in the duct using control box as template to mark the mounting screw holes. Remove
remote mounting.

unitG
GEE N
NE
and
Inspect
ERRdrill
AL
A L:: mounting holes. Mount unit to duct with sheet metal screws. Connect high and
heater for
Inspect heater for any
any possible
possible shipping
shipping damage.
damage.CheckCheckallallinsulators
insulators
lowcould
forvoltage
for breakage
breakage supplies
and
and inspect heater
inspect along
heater element
elementwith fan
wire for
wire for interlock
anydeformation
any deformationthat circuit (if no airflow switch is furnished). Larger
that
could cause a short
cause a short circuit
circuit or
or ground.
ground. Make
Make sure
sureallallfasteners
fastenersare
aretight.
tight.
heaters
Electricalmay
Electrical
tightness.
require
connections
connections such as
such ashangers.
pressure terminals
pressure terminalsshould
shouldbe bechecked
checkedfor for
tightness.
To Iinstall
NSTALLaATflangeION: type heater FIGURE 5.3.1, insert heater between two sections of flanged duct
andForbolt in place.
safe operation and best
procedures must be adhered
Forperformance,
additional
best performance,
adhered to. to.
strength,
the following
the the duct flange should be doubled as shown in the
followinginstallation
installation

STALLATIONfigure.
MANLarge UAL heaters may require hanger straps. Connect high and low voltage supplies along
Heaters may be installed
installed in
in the
the sides
sides of
of either
either horizontal
horizontalororvertical
vertical
with fan
ducts but interlock topcircuit
never in the top or bottom
or (if
bottom of no airflow
of aa horizontal
horizontal switch is furnished).
duct.Heaters
duct. Heaters

CO DUCT Hinstalled
EATin E RS
installed in vertical ducts are tested and approved for up airflow only!
vertical ducts are tested and approved for up airflow only!

1.Install a heater a minimum

minimum of
of (4)
(4) feet
feet from
from heat
heatpumps
pumpsor
orcentral
centralair
air
conditioners.
uct Heater
2. At least 4 feet downstream
downstream from
from an
an air
air handler.
handler.
s, air 3. At least 2 feet either side
side of
of an
an elbow
elbow or
or turn.
turn.
controlled by
4. At least 4 feet from any
any canvas
canvas duct
duct connector
connectoror
ortransition
transitionsection
sectionfor
for
change in duct size.
600 volts, both
5. At least 4 feet downstream
downstream from
from an
an air
air filter.
filter.
xcept for the DD WRAPPER 4 feet upstream from a humidifier.
6. At least upstream from a humidifier.
rol panel for FRAME
Refer to the back of this sheet
sheet for:
for: duct,
duct, electrical
electricaland
andair
airvelocity
velocity
FRAME
requirements.

k all insulators To install a slip-in heater

heater FIG.1,
FIG.1, cut
cut an
an opening,
opening,as asrequired
requiredininthe
theside
side
eformation that of the
of the duct.
duct. Slide
Slide heater
heater in
in the
the duct
duct using
using control
control box
boxasastemplate
templatetoto
eners are tight. mark the
mark the mounting
mounting screw
screw holes.
holes. Remove
Remove unitunit and
anddrill
drillmounting
mountingholes.
holes.
d be checked for Mount unit
Mount unit to
to duct
duct with
with sheet
sheet metal
metal screws.
screws. Connect
Connecthighhighandandlow
low
voltage supplies
voltage supplies along
along with
with fan
fan interlock
interlock circuit
circuit(if
(ifno
noairflow
airflowswitch
switchisis
furnished). Larger heaters may requireHEATING
hangers.
furnished). Larger heaters may require hangers. HEATING
ELEMENTS
To install
To install a
a flange
flange type
type heater
heater FIG.2,
FIG.2, Insert
Insert heater
heaterbetween
betweentwo
twosections
sections ELEMENTS
installation of flanged
of flanged duct
duct and
and bolt inTERMINAL
bolt in place.
place. For OR
For additional
additional strength,
strength,the
theduct
ductflange
flange TERMINAL OR
should be doubled as
should be doubled as shown shown in the figure.
in the figure. Large
Large heaters mayrequire
heaters may require
hanger straps. CONTROL BOX CONTROL BOX
l or vertical hanger straps. Connect
Connect highhigh and
and low
low voltage
voltage supplies
suppliesalong
alongwith
withfan
fan
interlock circuit
interlock circuit (if
(if no
no airflow
airflow switch
switch is is furnished).
furnished).
Heaters
p airflow only!
FIGURE 5.3.0 SLIP-IN HEATER INSTALLATION FIGURE 5.3.1 FLANGE HEATER INSTALLATION
s or central air
INC.
INC.
See Figure 5.3.2 for examples of some
500 common
500 GOULD
GOULDDRIVE
installation
DRIVE
approaches.
COOKEVILLE,
COOKEVILLE,TN
TN 38506
38506
FAX
FAX (931)432-4140
(931)432-4140 PHONE
PHONE(931)432-4141
(931)432-4141

nsition section for 06-4141-00 REV. C E.C.O. 10438

06-4141-00 REV. C E.C.O. 10438

HORIZONTAL DUCT & AIRFLOW WITH

HORIZONTAL DUCT & AIRFLOW
VERTICAL
V E R TICA L DUCT
DUC T&&AIREFLOW
A IR FLOW
VERTICAL DUCT & AIRFLOW
with HORIZONTAL INSTALLATION
HORIZONTAL INSTALLATION
BASE HEATER BASE HEATER
r velocity FLIPPED 180°
FLIPPED 180°

AIRDUCT
AIR DUCT
AIRFLOW
AIRFLOW

ired in the side

template to SLIP-IN
mounting holes. CONSTRUCTION
gh and low
SLIP-ON
SHOWN
low switch is CONSTRUCTION
A
SHOWN IR
AIR
FL
FLO
OWW
BASE
BASE
HEATER
een two sections HEATER
, the duct flange
s may require
long with fan

BASE
BASE
AIRFLOW

'H'
A
AIR
I RF
HEATER
HEATER
FLO
LW
AIRFLOW

O
W

INC.
ULD DRIVE COOKEVILLE, TNBASE HEATER
38506 'W'
BASE HEATER
* ONE HEATER - 4
* ONE HEATER- 4
ROTATED 180°
ROTATED 180

1)432-4140 PHONE (931)432-4141 * O POSITIONS

 NE HE ATE R -
POSITIONS * EONE
* S A M HEATER
HE ATE R - -
4 PO S ITI O N S * FOSAMER VHEATER-
E R TICAFOR
L DUC T S
FOR VERTICAL
VERTICAL DUCTS

06-4141-00 REV. C E.C.O. 10438 DUCTS

FIGURE: 4

FIGURE 5.3.2 COMMON INSTALLATION APPROACHES

1.800.627.4499 27
 START-UP
ACCESSORY EK-Series Electric Duct Heater

6.0 OPERATING INSTRUCTIONS

WARNING
This electric duct heater
is intended for heating
general ventilation air only.
Do not use in airstreams
containing hazardous or
explosive materials or
vapors.
NOTE: Minimum
airflow or greater
must be maintained
uniformly over the
entire face of the heater.
The velocity of air should
NEVER be lower than
the specified minimum.
In cases where this is
not true the kW must be
reduced or the velocity of
air increased.
6.1 ELECTRICAL REQUIREMENTS
Refer to attached wiring diagram and wiring diagram on inside of cover. Make sure line and
control voltage of system matches that noted on wiring diagram.
Wire in accordance with N.E.C. and any existing local codes.
Check tightness of all factory and field electrical connections.
Make sure fan interlock is wired in if the Heater does not have an air flow switch.
Use 90 deg. C (194 deg. F) copper wire.
Control must be wired for N.E.C. Class 1 unless otherwise specified.
When Heater has integral transformer for control voltage to thermostat, use thermostat with
isolating contacts to prevent interconnection of Class 2 outputs.
Disconnect all electrical power before servicing. When servicing heater, make sure all
components are repositioned in the proper location and reconnect per wiring diagram.
Replacement parts must be identical to the original components.
Contact factory for replacement parts.

NOTE: Observe at
least one heating cy-
cle to verify proper
operation; ensure
that safety limit controls
do not occur under normal
operating conditions before
leaving the installation.
6.2 GENERAL OPERATING REQUIREMENTS
Minimum Air Velocity: 70 CFM per KW (75-80 Recommended)
Maximum Inlet Air Temperature: 100 Deg. F
Maximum Heater KW: 3 0 KW per square foot of duct cross section (EK-series)
Most models may be flipped and rotated.

NOTE: The air tem-

perature entering
the heater should
not exceed that
marked on the heater
nameplate label.

28 1.800.627.4499
 MAINTENANCE
EK-Series Electric Duct Heater ACCESSORY

7.0 MAINTENANCE WARNING

All RenewAire heaters are designed to be maintenance free and operate for a long time without
problems. DO NOT ATTEMPT TO
CLEAN OR SERVICE WITH-
The following are a few steps that are recommended:
OUT DISCONNECTING ALL
1. Periodic inspection of the heater to check for any accumulation of dust on heating elements, SOURCES OF POWER
any signs of rusting in the control panel and to check for any heater frame damage due to
over heating.
2. P eriodic inspection of the following heater components (during and before heating season):
a. All fuses
b. Resistance from phase to phase for each circuit
c. Electrical connections to all contactors and heating elements
d. All contactors
e. Step controllers and modulating valves (SCR)
3. A lways replace defective components with original parts. Contact factory for replacement
parts.

7.1 SERVICE PARTS

All RenewAire electric heaters are designed to be maintenance free and operate for a long time
without problems.
The following are recommended steps:
u P erform annual maintenance and inspections as shown in Section 7.0 Maintenance in this
manual.
u If defective parts are discovered, replace them with only factory-original parts.
u If repair parts are needed, see Section 8.0 Factory Assistance.

FIGURE 7.1.0 SERVICE PARTS

1.800.627.4499 29
 FACTORY ASSISTANCE
ACCESSORY EK-Series Electric Duct Heater

8.0 FACTORY ASSISTANCE

In the unlikely event that you need assistance from the factory for a specific issue with the
Electric Duct Heaer, make sure that you have the information called for in the Unit Records page
in the Owner Information section of this manual. The person you speak with at the factory will
need that information to properly identify the unit and the installed options.

TO CONTACT RENEWAIRE CUSTOMER SERVICE:

CALL 800-627-4499
EMAIL: RenewAireSupport@RenewAire.com

30 1.800.627.4499
 EK-Series Electric Duct Heater ACCESSORY

T H I S P A G E I S I N T E N T I O N A L LY L E F T B L A N K .

THIS PAGE IS INTENTIONALLY LEFT BLANK

1.800.627.4499 31
 About RenewAire
For over 30 years, RenewAire has been a pioneer in enhancing indoor air quality (IAQ)
in commercial and residential buildings of every size.This is achieved while maximizing
sustainability through our fifth-generation, static-plate, enthalpic-core Energy Recovery
Ventilators (ERVs) that optimize energy efficiency, lower capital costs via load reduction and
decrease operational expenses by minimizing equipment needs, resulting in significant energy
savings. Our ERVs are competitively priced, simple to install, easy to use and maintain and have
a quick payback. They also enjoy the industry’s best warranty with the lowest claims due to
long-term reliability derived from innovative design practices, expert workmanship and Quick
Response Manufacturing (QRM).

As the pioneer of static-plate core technology in North America, RenewAire is the largest ERV
producer in the USA. We’re committed to sustainable manufacturing and lessening our
environmental footprint, and to that end our Waunakee, WI plant is 100% powered by wind
turbines. The facility is also one of the few buildings worldwide to be LEED and Green Globes
certified, as well as having achieved ENERGY STAR Building status. In 2010, RenewAire joined
the Soler & Palau (S&P) Ventilation Group in order to provide direct access to the latest in energy-
efficient air-moving technologies. For more information, visit: renewaire.com

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