Model 4185 Air Cooled, Ceramic Reflector User Manual
Contents
1. Strip Instruction Manual INFRARED HEATERS Infrared Strip Heater Model 4185 StripIR Publication No 106991 001 Rev 1 June 2010 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 RESEARCH INC PROVIDING CONTROLLED ENERGY DRYING CURING HEATING Dear Customer Thank you for purchasing the Model 4185 StripIR We believe it is the finest system of its type and are confident you will think so too For technical assistance training replacement parts and assemblies or any other problems or questions contact our Field Service specialists They will do everything they can to help you or will put you in touch with someone who can This instruction manual has been carefully prepared to ensure you get all the capabilities out of your system we designed and built into it To tell us how we can make the system our support of it or this manual even more useful we invite you to call our product manager with your suggestions and recommendations Additional copies of this manual are available at reasonable cost from our Customer Service Department Once again let us welcome you to the growing family of Research Inc customers We look forward to working with you in the future Sincerely Terry Nigon President Research Inc Section 1 Introduction Features and Benes eee2. 1 2 anne nn nn anne 92525252 venda 1 2 Product 1 3 3 Power 6 1 4 Section 2 Safety Generaksia4qvavttm a Sao a Debate GETS 2 1 2 21 21 Electrical 0101 2 1 NIT IT 2 2 Section 3 Assembly Required TOONS 212 22 3 1 Reflector and Lamp Installation se e e e e K e K K K 3 1 Exploded AE EEE 3 1 Section 4 Installation Unpack and Check for Damage sss see e ee e 4 1 Required 7 005 4 1 Mechanical installation ee e nenene annen rr neern renerne n rnerr nenne 4 1 Heater Dimensions sss teens nennen anne nn 4 2 Wiring Power to Heater rannnnrnarananannnnnnnnerenenerennenenenenenen 4 3 Section 5 Maintenance edad devdeatodees bandene teres Sans 5 1 Lamp and Reflector Surface 3 0 5 1 Lamp Replacement sonit kanpin ra iaia a aka aa 5 1 Section 5 Product Information 0 2 1 5 1 Accessories Replacement Paria e 5 1 Figure 1 1 Model 4185 StripIR Heater Introduction The Model 4185 StripIR infrared heater is a lamp and formed reflector heating system that provides even heat distribution across a 1 7 wide strip The Model 4185 heater uses T 3 halogen lamps backed by a ceramic reflector to provide heat and offer the users benefits of a high density heating solution The Model 4185 StripIR infrared heaters are designed for use in any application that requires a clean responsive non contact heat source Some typical app
3. 4185 heater module maintain a high surface temperature The reflector material also serves as a re emitter of medium wave 3 to 4 microns infrared energy This can be beneficial in many processes depending on the absorptive properties of the material being heated Ceramic Reflector The ceramic reflector provides heat by re emitting medium wave and short wave energy Mounting The back of the Model 4185 has six 10 32 NF threaded holes for mounting purposes Product Temperatures The maximum work piece temperature depends upon a number of conditions the ability of the work piece to absorb radiant energy the amount of heat loss and the applied voltage to the heater emitter For continuous heating processes the maximum work piece temperature should be less than 1300 F 704 C Heat Flux Densities The Model 4185 can generate as much as 100 watts per linear inch 3 9 watts per mm Dissipated power for the heaters varies with heated length and is listed in Specifications Heat flux density is a product of the lamp type applied voltage and distance between the lamp and the target surface 1 2 Figure 1 2 Cylindrical Heating Figure 1 3 Web Drying Product Sizes A strip 1 7 inches in width and length from 5 to 38 inches 43 by 965 mm can be heated with a single Model 4185 Mounting two or more heaters side by side can create different heated areas For example Figure 3 shows eight heaters installed cylindrically to provide high
4. 0 controller includes potentiometer 4185 25 with Model 5420E 240 controller includes potentionmeter and timer 4185 25 with Model 5420mA 240 controller includes 4 10 mA input control Product Description 25 inch Strip heaters 2500 watt 4185 25 with Model 5420 480 controller includes potentiometer 4185 25 with Model 5420E 480 controller includes potentionmeter and timer 4185 25 with Model 5420mA 480 controller includes 4 10 mA input control Product Description 38 inch Strip heaters 3800watt 4185 38 with Model 5420 480 controller includes potentiometer 4185 38 with Model 5420E 480 controller includes potentionmeter and timer 4185 38 with Model 5420mA 480 controller includes 4 10 mA input control 6 2 Accessories Replacement Parts 103390 001 103390 003 103390 005 103390 007 103390 010 037 195 003 037 195 008 037 195 003 008 037195 007 008 037195 003 008 4185 05 500 4185 10 1000 4185 16 1600 4185 25 2500 4185 38 3800 5420 120 5420E 120 5420mA 120 5420 240 5420E 240 5420mA 240 5420 480 5420E 480 5420mA 480 MODEL 4185 Replacement Lamps all lamps sold in pairs 5 inch 500 watt 10 inch 1000 watt 16 inch 1600 watt 25 inch 2500 watt 38 inch 3800 watt Replacement Reflectors 05 inch length 1 per heater 10 inch length 1 per heater 16 inch length 1 each per heater 25 inch length Qty 1 007 and Qty 2 008 per heater 38 inch length Qty 1 003 and Qty 3 008 per heater H
5. 6 1600 01 00 4185 16 1600 02 00 4185 16 1600 03 00 4185 25 2500E 01 00 4185 25 2500E 02 00 4185 25 2500E 03 00 4185 25 2500 01 00 4185 25 2500 02 00 4184 25 2500 03 00 4185 38 3800 01 00 4185 38 3800 02 00 4185 38 3800 03 00 Ordering Information MODEL 4185 Product Description 5 inch Strip heaters 500 watt 4185 05 with Model 5420 120 controller includes potentiometer 4185 05 with Model 5420E 120 controller includes potentionmeter and timer 4185 05 with Model 5420mA 120 controller includes 4 10 mA input control Product Description 10 inch Strip heaters with EZ eye lamp 1000 watt 4185 10 with Model 5420 120 controller includes potentiometer 4185 10 with Model 5420E 120 controller includespotentionmeter and timer 4185 10 with Model 5420mA 120 controller includes 4 10 mA input control Product Description 10 inch Strip heaters 1000 watt 4185 10 with Model 5420 240 controller includes potentiometer 4185 10 with Model 5420E 240 controller includes potentionmeter and timer 4185 10 with Model 5420mA 240 controller includes 4 10 mA input control Product Description 16 inch Strip heaters 1600 watt 4185 16 with Model 5420 240 controller includes potentiometer 4185 16 with Model 5420E 240 controller includes potentionmeter and timer 4185 16 with Model 5420mA 240 controller includes 4 10 mA input control Product Description 25 inch Strip heater with EZ Eye lamps 2500 wait 4185 25 with Model 5420 24
6. CERAMIC 2P 10A LAMP QIH240 2000 V CER END 18 1 04 CABLE 14 3 TEFLON JACKET 200 C 19 1 106690 002 DENOTES PART NUMBERS LISTED ARE FOR MODEL 4185 10 CONSULT FACTORY FOR PART NUMBER CORRESPONDING TO YOUR MODEL 3 2 TOOLS REQUIRED MECHANICAL INSTALLATION Figure 4 1 Typical Installation for Model 4185 Heater Installation e Phillips Screwdriver NOTE Refer to Figures 4 1 Typical Installation Refer to Figure 4 2 Mounting Dimensions As shown in Figure 4 1 six 10 32 x 1 2 inch screws are provided on the top of the Model 4185 heater for mounting purposes The heater can be attached directly to a suitable frame structure or mounting brackets using these six screws Mount the heater so that the intended target absorbs the generated infrared energy yet not so close that the heater touches the target The heater should be mounted so that each end cover may easily be removed for lamp installation Multiple Model 4185 heaters can be mounted side by side to form large heating arrays Figure 4 2 Mounting Dimensions for Model 4185 Heater Dimension 4185 05 A 9 5 241 Overall Length Inches mm B Lighted 5 127 Length Inches mm END IEW LAMP CERAMIC SECTION REFLECTOR 1 DIMENSIONS STRIP IR 4185 4185 10 4185 16 4185 25 4185 38 14 5 368 20 5 521 29 5 749 42 5 1080 10 254 16 406 25 635 38 965 POWER INPT HOLE 875 22 DIA 2 BAC COVER STEEL VENT SLO
7. TS 1 50 63 38 16 MONTIN HOLES 10 32 NF 6 CONDIT FITTIN BS BAR CONNECTION ACCESS COVER SIDE IEW WIRING POWER All electrical wiring from the Model 4185 to the Model 5420 SCR Power TO HEATER Controller is included on Model 4185 units Refer to Model 5420 SCR Power Controller Instruction Manual for further wiring details 4 3 GENERAL LAMP AND REFLECTOR SURFACE MAINTENANCE LAMP REPLACEMENT 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 may become contaminated with smoke dust fingerprints or other 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 WARNING Disconnect the power cable from the power source and allow the heater to cool before continuing CAUTION 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 1 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 The ceramic reflector is a high temperature material with unlimited life and is essentially self cleaning CAUTION Wear soft clean oil free flannel or plast
8. afety rules you observe when you work with hot plates high intensity infrared heaters propane or acetylene torches soldering irons and other equipment that gets very hot 2 Remove all solids liquids and gases that burn easily from the area around the heater 3 Know where the nearest fire extinguisher is located and how to use it 4 Know how to put out fired from all the types of material near the Model 4185 Heater 2 2 UNPACK AND CHECK FOR DAMAGE REQUIRED TOOLS REFLECTOR AND LAMP INSTALLATION Assembly Remove the Model 4185 heater from its shipping container and associated packaging Check the entire unit for any potential damage due to shipping In the unlikely event damage has occurred keep all shipping containers and materials and file a damage claim with the shipping company that delivered the heater e Phillips Screwdriver e Pliers e Wire Stripper NOTE The Reflectors and Lamp are shipped separately and must be installed prior to operation Refer to Figures 3 1 Reflector and Lamp Assembly operations 1 Remove both Ceramic End Covers item 1 from both End Reflector assemblies item 4 2 Remove End Reflector assemblies item 4 from Heater Housing item 2 on the end opposite Power Cord item 19 3 Slide Reflectors item 3 into Heater Housing item 2 4 Reassemble End Reflector item 4 CAUTION Wear soft clean oil free flannel or plastic gloves when handling halogen quartz lamps Oils a
9. eater Modules 4184 05 500 Heater Module 4185 10 1000 Heater Module 4185 16 1600 Heater Module 4185 25 2500 Heater Module 4185 38 3800 Heater Module 120 volt Power Controllers Model 5420 120 Power Controller Model 5420E 120 Power Controller Model 5420mA Power Controller 240 Volt Power Controllers Model 5420 240 Power Controllers Model 5420E 240 Power Controllers Model 5420mA 240 Power Controllers 480 Power Controllers Model 5420 480 Power Controllers Model 5420E 480 Power Controllers Model 5420mA 480 Power Controllers 6 3 Accessories Replacement Parts continued 4184 4185 Ceramic Reflectors Replacement Part Numbers Heater Size Old Reflector Part Length Qty New Reflector Part Length Qty 5 037195 003 6 0 1 037195 003 6 00 1 10 037195 004 5 5 2 037195 008 11 0 1 16 037195 001 5 66 3 037195 008 11 0 1 037195 003 6 0 1 25 037 195 002 6 5 4 037195 008 11 0 2 037195 007 4 0 1 38 037 195 002 6 5 6 037195 008 11 0 3 037195 003 6 0 1
10. heat concentration on work piece objects Heating efficiency is highest on objects 1 inch or larger Figure 4 shows three heaters installed to provide heat to a moving web of material Additional heaters could be used in similar applications requiring greater heat flux density Lamps The Model 4185 utilizes high intensity short wave tungsten lamps The tungsten emitter in the lamps has an operating temperature of up to 4000 F 2205 C with a spectral energy peak wavelength of 1 15 microns Each heater requires one lamp to operate The Model 4185 will heat a strip that is 1 7 inch 43 mm wide and is available in heated lengths of 5 10 16 25 and 38 inches 127 254 406 635 and 965 mm Heated lengths should be at least 20 larger than work piece Power Controller The Model 4185 heater comes with the Research Inc Model 5420 SCR Power Controller A separate instruction manual for the Power Controller is included with the heater Figure 1 4 Model 4185 with Power Controller Safety GENERAL The Model 4185 Strip 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 accident or injury INFRARED CAUTION RADIATION Continuous exposure to high intensity i
11. ic gloves when handling quartz lamps If skin oils come in contact with the quartz tube the lamp will fail prematurely 1 Remove both end covers from the Model 4185 by removing the two screws from each end cover using the Phillips screwdriver Disconnect lamp leads from terminal blocks Grasp lamp end and pull the lamp out of heater Feed one end of the new lamp wire first into the lamp slot in end reflector through the heater and into the lamp slot on the heater s opposite end Connect lamp leads to terminal blocks Reinstall both end covers insert all four end cover screws and hand tighten each screw using the Phillips screwdriver 5 1 PoP Da Specifications Weight Ib kg Rated Voltage Power at Rated voltaae Lamp Optical Part to Order Product Information 4185 05 2 0 0 91 120 Volt 0 5 KW 103390 001 Clear 4185 05 500 Specification MODEL SPECIFICATIONS 4185 4185 10 4185 16 3 3 2 6 5 4 2 6 240 Volt 240 Volt 1 0 KW 1 0 KW 1 6 KW 097771 001 103390 003 103390 005 EZ eye Clear Clear 4185 10 4185 10 4185 16 1000E 1000 1600 6 1 4185 25 8 4 3 8 480 Volt 2 5 103390 007 Clear 4185 25 2500 4185 38 12 8 5 8 480 Volt 3 8 103390 010 Clear 4185 38 3800 4185 05 500 01 00 4185 05 500 02 00 4185 05 500 03 00 4185 10 1000E 01 00 4185 10 1000E 02 00 4185 10 1000E 03 00 4185 10 1000 01 00 4185 10 1000 02 00 4185 10 1000 03 00 4185 1
12. lications for the heater are listed below e Curing epoxy e Curing rubber coating on steel s Drying and Curing Paint e Drying and Curing adhesive e Forming plastic e Heating acrylic e Laminating e Preheating e Reglossing e Shrink Insulation e Thermoforming e Weld Stress Relief FEATURES AND BENEFITS HEATER DESCRIPTION e The lamps of these heaters heat up and cool down instantly in response to power control signals e They reach 90 percent of full operating temperature within three seconds of a cold start e The radiant energy dissipates to ten percent five seconds after the power supply is disconnected e Localized heat focuses only on the desired area without heating the rest of the product e The construction of these heaters combined with air cooling allows them to withstand continuous high temperature operation e Non contact heat source does not come in contact with product being heated s The infrared energy emitted from these heaters can be adjusted to match the heating requirements of a variety of applications e Repeatable results can be achieved for consistent process outputs e Integrated power controllers to control the operation of the heater e The ceramic reflector in the heater module is self cleaning in most applications This feature provides both high efficiency and low maintenance cost Heater Module The absorption emission characteristics of the ceramic reflector surfaces in the Model
13. nd contaminants are readily transmitted to the quartz by unprotected hands and can cause premature lamp failure 5 From the end of the assembly insert the Lamp item 18 through the End Reflector openings 6 Trim approximately 4 off each Lamp Lead then strip 25 of insulation off each Lamp Lead 7 Insert Lamp Lead into Terminal Blocks item 17 to make connections to power wiring Repeat at other end 8 Reassemble End Covers item 1 3 1 Figure 3 1 Reflector and Lamp Assembly 4185 38 42 50 38 INCH 4185 25 29 50 25 INCH 4185 16 20 50 16 INCH _ 4185 10 14 50 10 INCH A 4185 05 950 5 INCH 2 MODELNO OVERALLLENGTH DESCRIPTION COMPONENT NO QTY ITEM DESCRIPTION 037193 000 2 1 COVER END 4184 FAB COVER 4184 20 50 LG 2 1 037194 004 037195 004 2 3 REFL 4184 10 037197 000 2 4 FAB ASSY END REFLECTOR 037603 002 1 5 FAB COVER SAFETY 4184 16 054979 027 2 6 SCRW PH 4 40X1 SST PH 054979 105 8 7 SCRW PH 10 32X1 4 SST PH 054979 123 10 8 SCRW PH 10 32X 5 PH SS SEMS IN 055029 002 2 9 WASHER FLAT 4 SST 055307 017 2 10 NUT HEX 4 40 SST 055310 017 2 11 WASHER SPLIT 6 SST 055455 011 4 12 WASHER LOCK 10 INT ZI 055729 004 1 13 PLUG BUTTON 7 8 DIA 060512 001 1 14 STRAIN RELIEF BUSHING 095180 006 2 15 LABEL THERMAL BARCODE 2X1 098901 001 1 16 LABEL HOT SURFACE UL IEC 5041 100571 001 2 17 TERMINAL BLOCK
14. nfrared 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 Parts of the heater may exceed 500 F 260 C Contact with the lamps reflectors or TEMPERATURES 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 There is danger of electrical shock when servicing the heater SAFETY CAUTION 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 3 for proper installation procedures FIRE SAFETY WARNING 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 the heater end covers removed 1 Obey the same fire s
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