Chromalox U-RAD PG405-5 User's Manual
Contents
1. 032 075525 012 9 0 1 2 Flexible Conduit Connector and Locknut 119 075454 005 MISCELLANEOUS HARDWARE pn 5 ded 20007548209 O PEB2NUE sss eme Terminal S 248 046044 002 8 32 x 1 3 4 248 075512 194 ermilal oCLOW ace 5 een HONE Se RR ELA ERE E a 8 32 x1 PRN ET 248 075512 185 Element Support Clip ien eeu 059 014304 002 8 Washer 328 075528 036 Note Part Numbers suffixed by a number in indicates the number of parts of the same part number used or supplied if more than one RENEWAL PARTS IDENTIFICATION EIER ti rms Housing TU 3 120V TU 3 208V TU 3 240V TU 3 275V TU 4 208V TU 4 240V TU 4 275V TU 4 480V TU 5 208V TU 5 240V TU 5 275V TU 5 480V TU 6 208V TU 6 240V TU 6 275V TU 6 480V TU 7 208V TU 7 240V TU 7 275V TU 7 480V TU 2 2 120V TU 2 2 208V TU 2 2 240V TU 2 2 275V TU 3 120V 234 016383 002 TU 2 120V 234 016383 001 TU 3 208V 234 016383 002 TU 2 208V 234 016383 001 TU 3 240V 234 016383 002 TU 2 240V 234 016383 001 TU 3 275V 234 016383 002 TU 2 275V 234 016383 001 TU 3 2 120V TU 3 2 208V TU 3 2 240V TU 3 2 275V TU 4 208V 234 016383 003 TU 2 208V 234 016383 001 TU 4 240V 234 016383 003 TU 2 240V 234 016383 001 TU 4 275V 234 016383 003 TU 2 275V 234 016383 001 234 016383 002 152 016384 002 Element 232. 01 1571837601 Urr 2aeoieass 006 152016376015 U 6 275V 234 016383 005 UTU 5 275V 234 016383 004 U 2 275V 234 016383 001 UTU 7 480V 234 016383 006 U 6 208V 234 016383 005 UTU 5 480V 234 016383 004 U 3 208V 234 016383 002 UTU 7 208V 234 016383 006 U 6 240V 234 016383 005 UTU 6 208V 234 016383 005 U 3 240V 234 016383 002 192 016376 012 UTU 7 240V 234 016383 006 39780 234 016983 000 234 016282 006 192 016076019 U 6 208V 234 016383 005 UTU 6 275V 234 016383 005 U 4 208V 234 016383 003 UTU 7 480V 234 016383 006 U 6 240V 234 016383 005 U 234 016383 005 U 4 240V 234 016383 003 U 234 016383 006 2 152 016376 013 U 6 275V 234 016383 005 U 234 016383 006 2 457 016376 020 U 4 275V 234 016383 003 U 234 016383 006 2 U 6 480V 234 016383 005 U 234 016383 006 2 U 4 480V 234 016383 003 STANDARD PARTS USED ON ALL HEATERS G Iur PET Tu 303 014316 001 3 Insulating 5 032 013454 001 6 Terminal BIOCK Eggs 303 014317 001 Bushing Retaining Clip 059 017175 001 CI Terminal GOVer eene rei etel d 080 016868 001 3 Mounting Clamp Parts Bag For mounting heaters with overall length less than Bracket is ese c 027 016372 001 74 1 2 use Parts Bag 168 013071 001 For heaters with 74 1 2 or larger over all length use Parts Bag 168 013071 002 9 Spacer Bushing
3. 4 016383 003 152 016384 003 Assembly 234 016383 004 152 016384 004 234 016383 005 152 016384 005 234 016383 006 152 016384 006 234 016383 001 2 152 016376 001 U RAD 32 152 016376 002 D Element assembly includes all parts shown except item 3 For element assembly number add prefix to Element part number 2 Ex UTU 6 208V ESTEE TRE Housing UTU 2 120V UTU 2 208V UTU 2 240V 234 016383 001 152 016384 001 UTU 2 275V 234 016383 002 2 152 016376 003 U RAD 42 152 016376 004 Limited Warranty Please refer to the Chromalox limited warranty applicable to this product at http Avww chromalox com customer service policies termsofsale aspx Chromalox PRECISION HEAT AND CONTROL 2150 N RULON WHITE BLVD OGDEN UT 84404 Phone 1 800 368 2493 www chromalox com
4. Chromalox Installation Operation SERVICE REFERENCE and RENEWAL PARTS IDENTIFICATION Sas EE 161 048457 001 APRIL 2005 Type U RAD Electric Radiant Heaters Conduit Connector a Single Element U RAD Double Element U RAD as AB Safety Alert Symbol used to indicate Length lengh in risk of personal injury Please familiarize yourself with these instructions before Overatt Heated attempting to install or operate this Radiant Heater Before Installing 120 or 240 25 1 2 16 5 8 1 Open carton and remove heater at the place of installation 208 or 275 Mounting clamps are in parts bag in carton li 120 or 240 28 19 3 4 8 5 8 3 2 Check nameplate volt and watt rating against your power supply 8 n or s or voltage and heating requirements of your installation This nameplate is located on one end of the heater 208 or 275 31 3 4 22 78 i s 36916 27 11 16 AWARNING 208 275 39 11 16 30 13 16 240 208 or 275 The system designer is responsible for the safety of ve 47 346 38 11 16 this equipment and should install adequate back up E 208 or 275 controls and safety devices with their electric heat 2 240 44 35 1 8 ing equipment Where the consequences of failure 208 275 47 18 38 1 4 could result in personal injury or property damage 240 i back up controls are esse
5. U 3 275V 234 016383 002 UTU 5 275V 234 016383 004 U 4 2 208V UTU 6 480V 234 016383 005 U 4 2 240V 234 016383 003 2 152 016376 006 UTU 5 480V 234 016383 004 U 4 2 275V UTU 6 2 208V 234 016383 005 U 5 208V 234 016383 004 UTU 6 2 240V 234 016383 005 2 452 016376 015 U 2 208V 234 016383 001 UTU 6 2 275V 234 016383 005 U 5 240V 234 016383 004 UTU 6 2 480V 234 016383 005 U 2 240V 234 016383 001 192 016376 007 UTU 7 208V 234 016383 006 U 5 275V 234 016383 004 UTU 2 208V 234 016383 001 S UNE nb T U 3 208V 234 016383 002 UTU 7 275V 234 016383 006 U 5 240V 234 016383 004 UTU 2 275V 234 016383 001 U 3 240V 234 016383 002 192 016376 008 UTU 7 208V 231 016383 006 U 5 275V 234 016383 004 UTU 3 208V 234 016383 002 U 208 234018383 004 UTU324V 234016383002 15701637617 U 4 208V 234 016383 003 UTU 7 275V 234 016383 006 U 5 240V 234 016383 004 UTU 3 275V 234 016383 002 275 234016383004 52016376009 UTU L200V 234 016383 003 U 4 275V 234 016383 003 UTU 7 240V 234 016383 006 U 5 480V 234 016383 004 UTU 4 240V 234 016383 003 459 016376 018 U 4 480V 234 016383 003 UTU 7 275V 234 016383 006 U 5 2 208V 234 016383 004 UTU 4 275V 234 016383 003 0 5 2 240 234 016383 004 2 155 15376910 UTU 7 480V 234 016383 006 U 5 2 275V 234 016383 004 UTU 4 480V 234 016383 003 UG GUY 234016383 005 UTUS20 29401638004 U 2 208V 234 016383 001 UTU 7 240V 234 016383 006 U2240 234 016383 0
6. d slide element assembly out of housing Disconnect heating element from electrical leads at both ends Remove screws from porcelain terminal blocks Remove element support clips and secondary insulating bushings 5 Lift element out of heater 5m B To Install Element Observe instructions for removing element and proceed in reverse fashion Be sure to replace secondary insulating bushings C Care of Reflectors Reflectors should be cleaned periodically A mild soap and water solution or fine cleaning powder is best although more drastic means may be required if reflectors are badly soiled by chemical or other deposits The reflector is aluminum DO NOT use alkali cleaners since alkalies will dull reflector Mild non alkaline cleaners such as used for scouring kitchen sinks may be used Reflectors are replaceable and may be purchased from Chromalox RENEWAL PARTS IDENTIFICATION Reflector Aluminum Reflector Aluminum Housing Housing U 4 208V 234 016383 003 UTU 6 208V 234 016383 005 U 3 208V 234 016383 002 UTU 5 208V 234 016383 004 U 4 240V 234 016383 003 UTU 6 240V 234 016383 005 U 3 240V 234 016383 002 192 016376 005 UTU 5 240V 234 016383 004 459 016376 014 U 4 275V 234 016383 003 UTU 6 275V 234 016383 005
7. e fibrous insulation A suggested method of accomplishing this is indicated in Fig 4 7 Ventilation Where solvents water etc are being evaporat ed from work in process it is necessary to provide substantial quantities of ventilation air to carry away the resulting vapors AWARNING FIRE HAZARD Since Radiant heaters are capable of developing high temperatures extreme care should be taken to A Keep combustible materials at least 6 away form sides and back of heater housing and its sup porting brackets and spaced far enough in front of heater heating element side so thermal radiation from the elements will not ignite combustible materials B If combustible materials are being processed stoppage of process should initiate immediate heater shutdown and interception of residual heat from radiant heaters use radiation baffles or move heaters away from work C In the case of solvents of an explosive nature ventilation air must be in sufficient volume to dilute the solvent vapor so that explosive mixtures cannot occur refer to NFPA 86 Standard for Ovens and Furnaces WIRING ELECTRIC SHOCK HAZARD Disconnect all power before installing or servicing heater Failure to do so could result in personal injury or property dam age Heater must be installed or serviced by a qualified person in accordance with the National Electrical Code NFPA 70 AWARNING ELECTRIC SHOCK HAZARD Any installation involving electric h
8. eaters must be performed by a qualified person and must be effectively grounded in accordance with the National Electrical Code to eliminate shock hazard 1 Electrical connection to the type U RAD Radiant Heater is made through the 7 8 dia opening in the end of the terminal cover of the element assembly A 1 2 flexible conduit connector is provided with each element assembly for this purpose 2 Wiring should be run in flexible or rigid metal conduit and must be installed in accordance with the requirements of the National Electrical Code and such other local requirements by a qualified per son as defined in the NEC 3 Access to the element terminals is obtained by removing the mounting bolt and nut see Figure 8 item and and slid ing the terminal end of the element assembly out of the housing 4 Wires supplying power to heating element terminals shall have insulation rated for 150 C minimum High temperatures will oxidize copper Use only nickel plated copper wire for supplying power to heater Do not use aluminum conductors 5 A sufficient length of this wire not less than 12 should be used to extend from each heater terminal into a connection box location where the temperature does not exceed 300 F 6 Assemble terminal screw and wire as shown in Fig 5 Figure 5 7 Hold terminal with pliers and tighten the terminal screw securely with a screwdriver Note Where circuit wiring is installed in location
9. hown in Fig 2 Clamp assembly may be attached to heater by sliding over end or by snapping over top of extruded frame section at any point along its length see Fig 3 For proper heater support the max imum distance between clamps must not exceed 48 On extra long heaters more than two clamps are furnished 2 15 16 Figure 2 Figure 3 3 Mounting Holes When heaters are mounted adjacent to each other in the same plane note that distance between mounting holes on framing to support heaters will be 3 11 16 minimum When heaters are not in the same plane i e set at an angle to one another distance between mounting holes in framing will be either greater or less than 3 11 16 4 Framing Where an extensive installation is being made the use of continuous slot metal framing manufactured by sev eral concerns will be of assistance in saving time and money The frame is reusable Mounting Frame 2 Spacer Sheet Figure 4 5 Reflector Spacer Sheets Where heaters are not mounted side by side see Fig 4 reflector spacer sheets can be used between heaters These reflector spacer sheets and companion reflectors consisting of an extruded aluminum housing with reflector sheet and mounting clamps are available Check with local sales representative 6 Insulation Where unusually high work temperatures are encountered it may be desirable to insulate backs of heaters with high temperatur
10. lation B Maximum Ambient Temperatures CHROMALOX Radiant Heaters are not recommended for applications in ambient temperature exceeding 450 F Higher ambient temperatures mean shorter heater life Maximum work temperature in a given time depends on sever al factors Reflectivity of work specific heat of work mass of work kW input and losses from oven and time of exposure As work temperature increases the work loses heat by radiation and by convection to the surrounding ambient Although it is a gen eral principle of Radiant Heater application that work tempera ture conventionally exceeds ambient temperature in cases where extremely high work temperatures are desired it is nec essary to enclose the heaters in order to increase the ambient If evaporation of a liquid is desired as a result of increasing work temperature it is necessary to provide ventilation air in order to carry away the evaporated liquid Under carefully engineered circumstances a maximum work temperature of 600 F may be attained MAINTENANCE AWARNING ELECTRIC SHOCK HAZARD Disconnect all power before installing or servicing heater Failure to do so could result in personal injury or property dam age Heater must be installed or serviced by a qual ified person in accordance with the National Electrical Code NFPA 70 A To Remove Heating Element 1 Remove element assembly mounting nut and bolt and and element support clips see Figure 8 an
11. ntial 208 or 275 55 116 46 3 16 240 or 480 208 or 275 240 or 480 62 7 16 53 9 16 208 or 275 o wA 50 41 18 Specifications Table 208 or 275 240 53 1 8 44 1 4 208 or 275 240 or 480 208 or 275 240 or 480 208 or 275 240 or 480 208 or 275 240 208 or 275 240 208 or 275 240 or 480 208 or 275 240 or 480 208 or 275 240 or 480 208 or 275 240 or 480 61 1 16 52 3 16 Length In Single U Shaped Element 120 or 240 B 208 or 275 12 3 4 8 5 16 120 or 240 208 or 275 208 or 275 P 240 or 480 23 13 16 19 3 8 208 or 275 240 or 480 31 1 4 26 13 16 208 or 275 240 or 480 208 or 275 240 or 480 43 3 8 38 15 16 68 1 2 59 5 8 74 1 2 65 5 8 15 7 8 11 7 16 mem nem 59 1 4 50 3 8 67 1 8 58 1 4 37 1 4 32 13 16 74 1 2 65 5 8 80 5 8 71 3 4 86 3 4 77 788 2010 Chromalox Inc INSTALLATION AWARNING ELECTRIC SHOCK HAZARD Disconnect all power before installing or servicing heater Failure to do so could result in personal injury or property dam age Heater must be installed or serviced by a qual ified person in accordance with the National Electrical Code NFPA 70 te Mounting Clamp Assembly Terminal Cover Terminal Block Mounting 1 These radiant heaters are designed for indoor installation only 2 Clamps Heaters are mounted by means of the mounting clamp and 3 8 bolt assembly which is used as s
12. om bustible atmospheres are present as defined in the National Electrical Code Failure to comply can result in personal injury or property damage Before energizing this heater 1 Be sure all electrical connections are tightly made Hold ter minal with pliers when tightening screw 2 Be sure that all conductors are properly insulated 3 Be sure that all element assemblies have been properly replaced and that secondary insulation bushings have not been omitted A Controlling Radiant Intensity Standard Radiant Heaters are built to operate at approximately 40 watts per sq inch on the element sheath When it is desired to reduce radiant intensity one or more of the following meth ods may be used 1 INPUT CONTROLLERS These motor driven cycling devices can be used to vary heater output capacity from 4 to 100 They are usually connected in holding coil circuit of magnetic contactors See Chromalox Radiant Heater Manual for further information regarding Input Controllers and Contactors 2 SOLID STATE THYRISTOR POWER CON TROLLERS For best non contact control of radiant heat a Series 6 Chromalox Thyristor Power Controller with manual poten tiometer setting is recommended Truly proportional output of from 0 100 can be easily dialed in to suit the particular product or process requirements The Series 6 panels are pre engineered pre packaged assemblies in an enclosure with circuit disconnect provided and ready for instal
13. s of high ambient temperature conductors should be insulated in accor dance with requirements for temperature and voltage Wrong Right f Radiant lt 2 Heaters T e e L1 L2 Figure 6 8 SERIES CONNECTION of Radiant Heaters of equal volt and watt rating is permitted in all line voltages up to 600 volts In making such series connections it is necessary to observe the right series parallel connection rather than the wrong parallel series connection both shown in Figure 6 If heaters are connected according to the wrong illustration failure of any one heater will cause progressive failure of other heaters still operating 3 Conductors in 1 Conduit Radiant F Heaters 3 Conductors in 1 Conduit Figure 7 9 DELTA CONNECTIONS When heaters occur in multi ples of three they may be connected to and balanced across three phase lines The most commonly used connection is the delta connection illustrated in Figure 7 Three phase Delta connections to minimize inductive effect in conduits are made per this diagram The rule run all 3 three phase conductors in the same conduit as far as possible For sin gle phase run only two conductors and follow the same rule OPERATION FIRE EXPOSION HAZARD This heater is not intended for use in hazardous atmospheres where flammable vapors gases liquids or other c
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