ChamberIR E4 User Manual - Precision Control Systems, Inc.
Contents
1. 1 2 3 4 5 Time sec Applications 0 1 2 5 mm OD Silicone Wire 275 C Low Temperature Applications e E4 25 with 2500 watt lamps Most pre and post plastics and rubber extrusion applications are low temperature under 400 C Under these conditions it is only necessary to provide water cooling to the reflectors to allow the heaters to run continuously The recommended maximum product diameter in these applications is 0 25 inch 6 mm The heater will accommodate product size up to 2 5 inches in OD however the heating will not be uniform around the circumference if the OD is greater than 0 25 inch 6 mm Refer to the Model 4069 product data sheet for uniform heating of larger materials High Temperature Applications The Model E4 may also be operated as a high temperature furnace Transient product temperatures to 2000 F 1100 C and continuous product temperatures to 1500 F 815 C can be achieved with the Model E4 Air cooling options A AA are recommended if operated in this mode Specimen Sizes The Chamber will accommodate specimens up to 2 50 inches in diameter When operating at high heat flux outputs lamp rated voltage or greater the specimen should be no less than 1 8th inch in diameter and of a length equal to lamp lighted length to prevent lamp damage Specimen Temperature Transient temperature up to 3000 F can be reached and higher specimen temperatures may be reached but at a risk of prema2. 1 below Figure 4 1 Connect power according to the appropriate circuit diagram shown in figure 4 2 using the appropriate voltage rating as listed in specification table 2 1 CIRCUIT SCHEMATICS MODELS E4 MODELS E4 6 10 16 Ye 295 A 38 Figure 4 2 Page 12 of 19 Cooling Water Connections 1 8 NPT tapped holes are provided for lamp reflector cooling water connections Clean water at 100 F maximum less than 100 psi must be supplied to the unit at flow rates indicated in specification table 2 1 for the appropriate sized Model E4 heater Deionized water is preffered Connect cooling water lines to water inlet and outlet ports such that water flows thru both halves of the unit at minimum flow rates given in specification table 2 1 ICAUTION Cooling Water exit temperatures not to exceed 150 F NOTE Cooling Flow is optional during short transient heating tests where reflector body temperatures will not exceed 350 F Lamp Installation E4 5 10 16 25 and 38 NOTE The 2000 watt per inch lamps 2000T3 and 5MT3 should be used for intermittent operation only with 50 duty cycle at rated voltage and a maximum on time of three minutes or if it is determined that the exit water temperature remains at 150 F or less during experimental runs higher duty cycles or maximum on times may be increased accordingly At no time should the reflector body exceed 350 F 1 Remove power to the heater Turning down the vol
3. 1 Unlock hinge fastener and open up unit 2 Center and locate specimen within Heating Chamber opening and if desired attach thermocouples to specimen 3 Close unit and lock hinge fastener 4 Turn on coolant water Check for leaks and obstructions in coolant flow lines 5 Select appropriate voltage level on power controller or input power source and switch power to On See table 2 1 for input voltage ratings for lamps used in appropriate model E4 6 Control heating rate for desired time interval and switch power to off 7 Allow heat to dissipate from heating chamber and specimen then open unit and remove specimen 8 Visually inspect lamps and interior reflector surfaces of heating chamber for foreign matter and contamination Clean if required before installing another specimen Refer to section 5 Maintenance for proper cleaning procedures Maximum specimen temperature depends on a Conduction and convection heat loss b Surface area c Reflectivity of specimen Up to 3000 F for short periods i e a few seconds is permissible where above parameters are relatively small Warning Do not exceed 2000 F continuous specimen setpoint temperatures Page 17 of 19 Maintenance Periodic inspection and removal of dirt and contaminants will ensure that equipment can be operated safely In dirty environments or heating operations the lamps amp reflectors may become contaminated with smoke dust fingerprints or other
4. emitter in the lamps has an operating temperature of 2500 K with a spectral energy peak wavelength of 1 15 microns Each Model E4 requires four lamps to operate The lamps are included with the Model E4 Water Cooling The Model E4 requires an external water cooling supply to cool the reflectors Refer to table 1 for flow rates depending upon model Benefits Fast T3 lamps heat up and cool down instantly in response to power control signals They reach 90 percent of full operating temperature within three seconds from a cold start The radiant energy Page 4 of 19 dissipates to ten percent within five seconds after power is removed The instant on off feature offers a great number of benefits to the user including reduced warm up and cool down times Focused T3 lamps have a small filament which allows the energy to be focused towards a target By focusing the IR the concentration of heat is greatly increased which allows small targets to see more thermal energy and allows higher process line speeds Controlled The ability to control the direction of the infrared heat along with rapid response allows higher heat transfer rates than with other infrared and convection systems Figure 2 shows the heating of a silicone jacketed wire Using an E4 the wire is heated to curing temperature in several seconds as compared to 2 to 5 times longer with other systems Temp C c838888 o
5. foreign matter When this occurs it is recommended that the lamp be cleaned Doing so will extend the life of the lamp and improve the heater s overall performance Use the following procedure IWARNING Disconnect the power cable from the power source and allow the heater to cool before continuing ICAUTION Wear soft clean oil free flannel or plastic gloves when handling quartz lamps If skin oils come in contact with the quartz tube the lamp will fail prematurely Cleaning Procedures Lamp Surfaces With a soft dry cloth or tissue wipe the residue from the lamps Household strength ammonia can be used to clean the lamps if necessary Reflector Surfaces With a soft dry cloth or tissue wipe the residue from the lamps Household strength ammonia can be used to clean the lamps if necessary In the event of high concentrations of contaminants it may be necessary to disassemble the unit clean and repolish the reflector surfaces to a specular finish Contact Research Inc Service for this Exterior Surfaces Periodic inspection for dirt and contaminations and a visual check of all water connections to assure they are leak proof will insure that equipment can be operated safely Page 18 of 19
6. Chamber Instruction Manual INFRARED HEATERS E4 ChamberlR Heater Another quality product from PROVIDING CONTROLLED ENERGY DRYING 4 CURING 4 HEATING 7128 Shady Oak Road e Eden Prairie MN 55344 952 949 9009 Fax 952 949 9559 www researchinc com salesOresearchinc com Contents COM Salt A A Nes cele ETETEA ENANS 2 Introductio A E E E E E E A E E ES 4 Description sti at sue tasted tte o R 4 MER TNS TCS a ace A 4 eN UDC A Soon E P EE dev nae ucts ase ssssaasaieas ascidaies anata eats os ax yan auauoad teu pace ease EE 5 Specifications ta 6 A e canal Manes ie Ae ol re coe oe aerate SD tae 6 Options and ACCESSORIES 55 sc3c5 ois diac amalha a Alii ia a Mateos ee 7 Lamps Hereni A AA as do AA A AA dal ad dels ida Sa ial A ti a ti 7 Quartz E oca 7 Observation WII ntcd sa sca ate coud adie Sale cytorSenslas at Gausluoatyateaiad a T N ae 7 Prgin Ports aiec a e A el e nero S a a EES 7 AOO ES aT EE EEE EEEE 8 RN 9 A 3 oi sca ET E casa E eda ae uat auc ads cos aoa ev gases cg act adeseee ent eee ee eae 9 cs O O CON 9 High Temperature do e adas 9 Electrical Satelital iii sia 9 O 10 station A AS 11 Mountings AAA k ol ape ene oth delay ee in eet a EES 11 POWER ONMCCHON T uastatea a 12 Cooling W ater Connections A eee ieee Bade ade Bae BAe ees 13 Lamp Installation E4 5 10 16 25 and 38 o ooooononococoncconoconocononcnonononcconnnnnnnnncnnnnnnccnnnnncnnnnnnos 13 Lamp Installation E4 02 06 ics chs htnak hace he
7. Replace as needed Install a new lamp and install the screw removed from the lamp contact in step 2 Tighten both screws Make sure the metal contacts of the lamp are in contact with the button contacts of the heater Install the lamp end covers Page 15 of 19 Operation General The following paragraphs describe the general principles of Infrared Heating and the detailed operation procedures for the Model E4 Quad Elliptical Heating Chamber Principals of Infrared Heating General Heat energy from a resistance element is transformed into infrared radiant energy at the surface of the heating element Infrared radiant energy passes through the air without heating it to the receiving object where it is absorbed and converted back into heat energy The receiving object then heats up Actually in an infrared installation the air does heat up but this is due to convection heating from the work piece reflector and lamp walls A substance ideally transparent to infrared energy converts none of the radiant energy to heat since the infrared energy passes through the substance A surface with high infrared absorptance characteristics converts almost all the infrared energy striking it into heat energy A surface having a low infrared absorptance characteristics reflect most of the radiant energy striking it All materials absorb some infrared energy and usually their absorptivity can be increased by coating the surface with a mater
8. a A 14 OS 16 Generalista id li os ios 16 Pricipal ot Infrared HA A A A A A at A 16 Operating Procedures E A O O E SE ES 17 A SN 18 CACA O e e nen do 18 Page 2 of 19 Page 3 of 19 Introduction The Model E4 elliptical chamber is designed for rapid heating of small size continuous materials such as tube cable and wire with an outer diameter from 0 25 to 0 125 inches in diameter It may also be used as a high temperature furnace in test applications The E4 is available in seven different lengths Typical applications for these heaters include Curing small diameter silicone tubing Re glossing small diameter plastic tubing Burning lubricant off extruded wire Curing coatings or adhesives on wire or cable Drying water from wire or cable Preheat wire or cable Description The Model E4 focuses high density infrared energy generated by T3 style halogen lamps onto a cylindrically shaped target area The heater is hinged so it can open and close ina clamshell style for easy access Reflectors Four elliptical reflectors See Figure 1 focus the infrared Ue aus Configuration energy supplied by T3 lamps toward the heater center axis The reflectors are constructed from aluminum polished to a specular finish and are available in heated lengths of 2 5 6 10 16 25 and 38 inches 51 127 152 254 406 635 and 965 mm Lamps Included are four high intensity short wave T3 style infrared lamps The tungsten
9. he heater end covers removed Page 9 of 19 Fire Safety 1 Obey the same fire safety rules you observe when you work with hot plates high intensity infrared heaters propane or acetylene torches soldering irons and other equipment that operates at high temperatures Remove all solids liquids and gases that burn easily from the area around the heater Know where the nearest fire extinguisher is located and how to use it 4 Know how to put out fire from all the types of material near the Model E4 Heater W m Page 10 of 19 Installation The following paragraphs describe mounting information power connections cooling water connections and lamp installation Mounting Information Fasten the Model E4 to a sturdy support bracket via the 4 4 20NC x 37 inch deep threaded holes on the side of the reflector block Center the unit so that specimens will be located in the focal axis Physical dimensions for all units are listed in table 4 1 Dimensions A and B Table 4 1 Model Number Dimension A Dimension B inches inches E4 2 2 50 E4 5 5 50 3 0 E4 6 7 40 3 0 E4 10 10 50 5 0 E4 16 16 50 5 0 E4 25 25 50 5 0 Note The E4 02 has only two 4 20 x 37 holes that are 1 apart centered 1 25 from the edge of the reflector Front View Page 11 of 19 Bottom View Power Connection Power connections to the heater are made using the attached power cord as shown in figure 4
10. ial which is a good infrared absorber Temperature Maximum workpiece temperature is dependent on 1 Heat Input Factors Radiation to workpiece area of workpiece being irradiated and absorptivity of workpiece 2 Heat Loss Factors Conduction to unheated masses convection losses and radiation to non reflective surface Highest workpiece temperatures are attained when heat input factors are high and heat loss factors are held to a minimum Overall efficiency is improved by blackening the heated side and insulating the unheated side of the workpiece Workpiece For highest efficiency the workpiece should have a dark non reflective high absorptance to infrared energy surface The workpiece should be located as close as possible to the focal line of the heater Instrumentation Workpiece temperature can be monitored by a thermocouple attached directly to the specimen For measuring temperature on a moving web workpiece an optical pyrometer may be used Power Controls Page 16 of 19 To control rapid rates in high response application a closed loop temperature controller should be used To reduce excessive inrush current always preheat lamp filament for at least Ya second before applying full voltage Operating Procedures The following procedures are used to operate the Model E4 Quad Elliptical Heating chamber Warning Prior to operation ensure all installation procedures are performed as described in section 4 Installation
11. models ordered with four purging ports See Figure 3 for Window placement Purging Ports Purging ports can be provided on two P or four PP opposing sides of the chamber wall This feature allows the heating environment to be force cooled or inert gas purged Purging ports will not function with a quartz liner installed See Figure 3 for purge port placement Page 7 of 19 Air Cooling Cooling ports provide added cooling to enhance lamp life Four A or eight AA air cooling ports can be provided along the length of the lamps Clean dry shop air should be used with the air cooling ports See Figure 3 for air cooling port placement Figure 3 Option Location FITTING lt NO SUPPLIED VIEW SHOWN W O END CASTINGS W PLUGS AND lt OPTIONS Option Codes additional machining required A Four port Air Cooling lamp cooling AA Eight port Air Cooling lamp cooling P Two port purge process cooling atmosphere PP Four port purge process cooling atmosphere W Observation Window Pyromter port diameter Page 8 of 19 Safety General The E4 ChamberlR Heater is designed for safe operation Nevertheless installation maintenance and operation of the heater can be dangerous for a careless operator or maintenance person For your safety and the safety of others please read the instructions in this INSTRUCTION MANUAL and follow these safety practices that will help to prevent acciden
12. s for the Model E4 are included with the heater Table 2 2 displays available lamps for replacement ordering Table 2 2 Lamps Heated Model P N Length Volts Watts Lamp Description 057550 002 2 Inches 120 1500 Q500T3 CL 057550 003 2 Inches 120 1000 Q1000T3 4CL 057541 001 5 Inches 120 500 S500T3 CL 057550 004 6 Inches 120 11500 Q1500T3 CL 057544 002 10 Inches 240 11000 1000 T3 2CL HT 057544 005 10 Inches 240 2000 2000 T3 CL HT 057541 004 16 Inches 240 1600 1600T3 CL 057541 008 16 Inches 240 3000 3000T3 CL 057541 005 25 Inches 480 2500 2500T3 CL 057549 001 25 Inches 480 2500 2500T3 VB CL 057544 008 25 Inches 600 5000 SMT3 1CL HT 057541 006 38 Inches 570 8800 3800T3 CL 057549 002 38 Inches 570 3800 3800T3 VB CL Standard lamp that ships in heater Lamps are for Horizontal Operation Only Quartz Liner A quartz liner can be provided to protect the reflectors in the heater from contaminants to maintain the reflectors at their maximum efficiency It has a 2 24 inch 57 mm outer diameter and a 2 09 inch 53 mm inner diameter Observation Window A 0 5 inch diameter window W with a quartz cover can be provided in the center of the chamber side wall to permit product viewing With the quartz cover removed product temperature can be measured with a suitable optical pyrometer The observation window is not available on
13. t or injury Infrared Radiation ICAUTION Continuous exposure to high intensity infrared radiation at close proximity could be harmful to eyes or skin Although infrared lamps are not emitting ultra violet electromagnetic radiation harmful burns could still result if an operator is in close contact with lamps being operated at high intensity Because of the brilliant light emitted by infrared lamps at full intensity it is recommended that the eyes be shielded from the glare if observing the lamps or radiant heat chamber for an extended period of time Use suitable shaded lenses or dark glasses High Temperatures Parts of the heater may exceed 500 F 260 C Contact with the lamps reflectors or metal parts near the lamps may cause severe BURNS WARNING NEVER place hands under the heating elements ALWAYS allow heating element to cool at least 5 minutes before touching the lamps or adjacent parts Electrical Safety There is danger of electrical shock when servicing the heater ICAUTION Observe that all applicable local and national electrical codes are met and a safe electrical ground system is installed before attempting to operate the heater Refer to the Section 4 for proper installation procedures ALWAYS disconnect the external power lines prior to servicing the heater ALWAYS disconnect the power lines AND any optional interlock circuits before installing or changing lamps NEVER operate the heater with t
14. tage to 0 VAC on a SCR controller does not remove power from the lamps 2 Remove both covers for the heater half that has the burned out lamp 3 With a volt meter check to insure voltage is removed from the heater 4 Loosen the screws on the bus bar that the lamp lead wires are wrapped around and remove wires from the screws Page 13 of 19 Remove the lamp Install a new lamp and center the lamp in the heater Wrap the lamp lead wires around the screws as shown in the picture Tighten bus bar screws and trim off the excess wire 7 Using a meter Ohm between the bus bar and ground checking for a short Install the lamp end covers NOTE Should lamp surfaces become contaminated with smoke dust fingerprints or other foreign material wipe clean before continuing operation or installation Lamp Installation E4 02 06 1 2 Remove power to the heater Turning down the voltage to 0 VAC on a SCR controller does not remove power from the lamps Remove both covers for the heater half that has the burned out lamp With a volt meter check to insure voltage is removed from the heater Locate the leaf spring style contact and remove the screw from the leaf spring that is closest to the lamp Loosen the remaining screw in the leaf spring so that it can be turned out of the way of the lamp Page 14 of 19 Remove the lamp Inspect the lamp contact points on both ends of the heater for damage
15. ture lamp failure A continuous set point of up to 2000 F may be achevied Shorter periods at constant temperature apply as specimen approaches maximum For highest specimen temperatures and heating rates specimen surface should be blackened to increase the absorptive characteristics Page 5 of 19 Specifications General Refer to the table 2 1 below for general specifications and ratings on the various models of E4 Table 2 1 Model No E4 2 E4 5 E4 6 E4 10 Weight Ibs 13 18 22 27 Lamp P N 057550 002 057550 003 057541 001 057550 004 057544 002 057544 005 Lighted Length 2 37 5 0 6 75 10 00 in Lamp Rated 120 120 120 240 240 240 Voltage Current 16 67 33 33 16 67 25 00 16 67 33 33 Amps Rated Power 2 0 4 0 2 0 6 0 4 0 8 0 KW Water Flow 25 49 25 74 49 98 gpm Operating 240 240 240 240 240 240 Voltage Model E4 16 E4 25 E4 38 No Weight Ibs 38 54 77 Lamp P N 057541 004 057541 008 057549 001 057544 008 057549 002 Lighted 16 0 25 0 38 0 Length in Lamp Rated 240 240 480 600 570 Voltage Current 26 67 50 0 20 83 33 33 26 67 Amps 29 55 480V 24 30 480V Rated Power 6 4 12 0 10 0 20 0 15 2 KW 14 18 480V 11 67 480V Water Flow 79 1 47 1 23 1 74 1 43 gpm Operating 240 240 480 480 480 Voltage Indicates Horizontal Operation Only Page 6 of 19 Options and Accessories Lamps Lamp
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