Chromalox DU-RAD-458 6.04 757 User Manual

(Supersedes PG423)

PG423-1

DU-RAD

161-057863-001

MARCH, 2004

4

and

Installation, Operation

RENEWAL PARTS IDENTIFICATION

Type DU-RAD Electric Radiant Heater

© 2010 Chromalox, Inc.

Specifications – Table A

Dimensions (In.)

BCD

A Total Center End

Model Volts kW Overall Heated Heated Heated

DU-RAD-458 6.04 75

7

/8 67 233/8 195/16
DU-RAD-466 6.42 797/8 71 323/8 195/16
DU-RAD-474 6.79 84 751/8 361/2 195/16
DU-RAD-482 7.17 881/16 791/8 409/16 195/16
DU-RAD-490 7.55 923/16 835/16 4411/16 195/16
DU-RAD-4102 208, 240, 8.12 983/16 895/16 5011/16 195/16
DU-RAD-4112 275 or 480 8.59 1035/16 947/16 5513/16 195/16
DU-RAD-4124 9.16 1091/2 1005/8 62 195/16
DU-RAD-4136 9.73 1151/2 1065/8 68 195/16
DU-RAD-4148 10.30 1215/8 1123/4 741/8 195/16
DU-RAD-4156 10.70 12511/16 11613/16 783/16 195/16
DU-RAD-4164 11.05 12913/16 12015/16 825/16 195/16
DU-RAD-4172 11.43 134 1251/8 861/2 195/16
DU-RAD-540 208, 240 6.60 815/8 723/4 191/4 263/4
DU-RAD-548 or 275 6.97 855/8 763/4 231/4 263/4
DU-RAD-558 7.44 903/4 817/8 283/8 263/4
DU-RAD-566 7.82 943/4 857/8 323/8 263/4
DU-RAD-574 8.19 987/8 90 361/2 263/4
DU-RAD-582 8.57 10215/16 941/16 409/16 263/4
DU-RAD-590 8.95 1071/16 983/16 4411/16 263/4
DU-RAD-5102 208, 240, 9.52 1131/16 1043/16 5011/16 263/4
DU-RAD-5112 275 or 480 9.99 1183/16 1095/16 5513/16 263/4
DU-RAD-5124 10.56 1243/8 1151/2 62 263/4
DU-RAD-5136 11.13 1303/8 1211/2 68 263/4
DU-RAD-5148 11.70 1361/2 1275/8 741/8 263/4
DU-RAD-5156 12.10 1409/16 13111/16 783/16 263/4
DU-RAD-5164 12.45 14411/16 13513/16 825/16 263/4
DU-RAD-5172 12.83 1487/8 140 861/2 263/4
DU-RAD-640 208, 240 7.60 933/4 847/8 191/4 3213/16
DU-RAD-648 or 275 7.97 973/4 887/8 231/4 3213/16
DU-RAD-658 8.44 1027/8 94 283/8 3213/16
DU-RAD-666 8.82 1067/8 98 323/8 3213/16
DU-RAD-674 9.19 111 1021/8 361/2 3213/16
DU-RAD-682 9.57 1151/16 1063/16 409/16 3213/16
DU-RAD-690 9.95 1193/16 1105/16 4411/16 3213/16
DU-RAD-6102 208, 240, 10.52 1253/16 1165/16 5011/16 3213/16
DU-RAD-6112 275 or 480 10.99 1305/16 1217/16 5513/16 3213/16
DU-RAD-6124 11.56 1361/2 1275/8 62 3213/16
DU-RAD-6136 12.13 1421/2 1335/8 68 3213/16
DU-RAD-6148 12.70 1485/8 1393/4 741/8 3213/16
DU-RAD-6156 13.10 15211/16 14313/16 783/16 3213/16
DU-RAD-6164 13.45 15613/16 14715/16 825/16 3213/16
DU-RAD-6172 13.83 161 1521/8 861/2 3213/16
DU-RAD-740 208, 240 8.80 106 971/8 191/4 3815/16
DU-RAD-748 or 275 9.17 110 1011/8 231/4 3815/16
DU-RAD-758 9.64 1151/8 1061/4 283/8 3815/16
DU-RAD-766 10.02 1191/8 1101/4 323/8 3815/16
DU-RAD-774 10.39 1231/4 1143/8 361/2 3815/16
DU-RAD-782 10.77 1275/16 1187/16 409/16 3815/16
DU-RAD-790 11.15 1317/16 1229/16 4411/16 3815/16
DU-RAD-7102 208, 240, 11.72 1377/16 1289/16 5011/16 3815/16
DU-RAD-7112 275 or 480 12.19 1429/16 13311/16 5513/16 3815/16
DU-RAD-7124 12.76 1483/4 1397/8 62 3815/16
DU-RAD-7136 13.33 1543/4 1457/8 68 3815/16
DU-RAD-7148 13.90 1607/8 152 741/8 3815/16
DU-RAD-7156 14.30 16415/16 1561/16 783/16 3815/16
DU-RAD-7164 14.65 1691/16 1603/16 825/16 3815/16
DU-RAD-7172 15.03 1731/4 1643/8 861/2 3815/16

Dimensions (In.)

BCD

A Total Center End

Model Volts kW Overall Heated Heated Heated

One Double-Hairpin Element Models

DU-RAD-040 120, 208 1.60 20

3

/8 1815/16
DU-RAD-048 240 or 275 1.97 2325/32 2225/32
DU-RAD-058 120, 208 2.44 287/8 2725/32
DU-RAD-066 240, 275 2.82 331/4 3125/32
DU-RAD-074 or 480 3.19 371/4 3525/32
DU-RAD-082 3.57 411/8 397/8
DU-RAD-090

208,

3.95 453/16 437/8
DU-RAD-0102 4.52 517/8 497/8
DU-RAD-0112

240,

4.99 563/16 547/8
DU-RAD-0124 5.56 621/2 6015/16
DU-RAD-0136

275

6.13 689/16 6615/16
DU-RAD-0148 6.70 751/2 7215/16
DU-RAD-0156

or

7.10 7813/16 77
DU-RAD-0164 7.45 82

11

/16 81

DU-RAD-0172

480

7.83 87 85

1

/16

Three Hairpin Element Models

DU-RAD-240 3.20 44

3

/4 357/8 191/4 85/16

DU-RAD-248

120, 208

3.57 483/4 397/8 231/4 85/16
DU-RAD-258

240 or 275

4.04 537/8 45 283/8 85/16
DU-RAD-266 4.42 577/8 49 323/8 85/16
DU-RAD-274 4.79 62 531/8 361/2 85/16
DU-RAD-282 5.17 661/16 573/16 409/16 85/16
DU-RAD-290 5.55 703/16 615/16 4411/16 85/16
DU-RAD-2102 6.12 769/16 675/16 5011/16 85/16
DU-RAD-2112 6.59 815/16 727/16 5513/16 85/16
DU-RAD-2124 208, 240 7.16 871/2 785/8 62 85/16
DU-RAD-2136 or 275 7.73 931/2 845/8 68 85/16
DU-RAD-2148 8.30 995/8 903/4 741/8 85/16
DU-RAD-2156 8.70 10311/16 9413/16 783/16 85/16
DU-RAD-2164 9.05 10713/16 9815/16 825/16 85/16
DU-RAD-2172 9.43 112 1031/8 861/2 85/16
DU-RAD-340 3.80 51 421/8 191/4 117/16
DU-RAD-348

120, 208

4.17 55 461/8 231/4 117/16
DU-RAD-358

240 or 275

4.64 601/8 511/4 283/8 117/16
DU-RAD-366 5.02 641/8 551/4 323/8 117/16
DU-RAD-374 5.39 681/4 593/8 361/2 117/16
DU-RAD-382 5.77 725/16 637/16 409/16 117/16
DU-RAD-390 6.15 767/16 679/16 4411/16 117/16
DU-RAD-3102 6.72 827/16 739/16 5011/16 117/16
DU-RAD-3112 7.19 879/16 7811/16 5513/16 117/16
DU-RAD-3124 7.76 933/4 847/8 62 117/16
DU-RAD-3136 208, 240 8.33 993/4 907/8 68 117/16
DU-RAD-3148 or 275 8.90 1057/8 97 741/8 117/16
DU-RAD-3156 9.30 10915/16 1013/16 783/16 117/16
DU-RAD-3164 9.65 1141/16 1053/16 825/16 117/16
DU-RAD-3172 10.03 1181/4 1093/8 861/2 117/16
DU-RAD-440 5.20 663/4 577/8 191/4 195/16
DU-RAD-448 5.57 703/4 617/8 231/4 195/16

Single Element

Three Elements

2

INSTALLATION

MOUNTING

The system designer is responsible for the safety
of this equipment and should install adequate
back-up controls and safety devices with their
electric heating equipment. Where the conse­quences of failure could result in personal injury or
property damage, back-up controls are essential.

Before Installing

1. Open carton and remove heater at the place of installation.

Mounting clamps are in parts bag in carton.

2. Check nameplate volt and watt rating against your power supply

voltage and heating requirements of your installation. This name­plate of the complete assembly is located on the back of the heater
housing. Note: Single element heaters have one nameplate. Three
element heaters have four nameplates (one for each element and
one for the complete assembly).

Housing

1 / "

7

8

Mounting Clamp

Assembly

Terminal

Cover

Terminal

Blocks

Polished Aluminum

Reflector

Element

Figure 1 — Heater Parts

and Dimensions

FIRE HAZARD. Since heaters are capable of devel­oping high temperatures, extreme care should be
taken to maintain adequate spacing between heater
and combustible materials. Failure to comply can
result in personal injury or property damage.

Mounting

1. Clamps — Heaters are mounted by means of the mounting clamp

and 3/8” bolt assembly which is used as shown 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 maximum dis­tance between clamps must not exceed 48”. On extra-long heaters,
more than two clamps are furnished.

2. Mounting Holes — When heaters are mounted adjacent to each

other in the same plane, the minimum distance will depend on
whether the wiring to the center element enters the terminal box
through the connector furnished or through a right angle connector
(not furnished).

3. Framing — Where an extensive installation is being made, the use

of continuous slot metal framing manufactured by several con­cerns will be of assistance in saving time and money. The framing
is reusable.

4. 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 factory or local
Chromalox Sales and Application Engineers.

5. Insulation — Where unusually high work temperatures are

encountered, it may be desirable to insulate with high temperature
insulation. Note: An air space should be left between backs of
heaters and insulation. (see Figure 4)

6. Ventilation — Where solvents, water, etc. are being evaporated

from work in process, it is necessary to provide substantial quanti­ties of ventilation air to carry away the resulting vapors.

IMPORTANT –

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. In order to comply with the standards of
safety required by the insurance companies, ventilation protection
and other facilities must be in accordance with NFPA Bulletin No.
86, entitled “Standard for Ovens and Furnaces”. This Bulletin
may be obtained from the Association at 470 Atlantic Avenue,
Boston Mass., 02110

FIRE/EXPLOSION HAZARD. This heater is not
intended for use in hazardous atmospheres where
flammable vapors, gases, liquids or other com­bustible atmospheres are present as defined in the
National Electrical Code. Failure to comply can
result in personal injury or property damage.

2 / "

15

16

2 / "

3

8

3 / "

11

16

Figure 2 Figure 3

Mounting Frame

Reflector
Spacer Sheet

Insulation

Figure 4

ELECTRIC SHOCK HAZARD. Disconnect all power
before installing or servicing heater. Failure to do
so could result in personal injury or property dam­age. Heater must be installed by a qualified person
in accordance with the National Electrical Code,
NFPA 70.

ELECTRIC SHOCK HAZARD. Any installation involv­ing electric heaters must be performed by a quali­fied person and must be effectively grounded in
accordance with the National Electrical Code to
eliminate shock hazard.

1. The power supply voltage should be the voltage as specified on the

heater nameplate located on the heater housing.

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 as may be
applicable. Note: High temperatures will oxidize copper. Do not
use copper wire in connecting this heater. Nickel-plated copper
wire, insulated in accordance with requirements for temperature
and voltage is recommended.

3. 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.

4. ELECTRICAL CONNECTIONS —
A. End Elements

Electrical connection to the heater end elements 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.

B. Center Elements

Electrical connection to the heater center element is made
through the 7/8” dia. opening in the 4” octagon conduit box for
the element assembly. A 1/2” flexible conduit connector is pro­vided with each element assembly for this purpose.

5. ACCESS TO TERMINALS
A. End Elements

Access to the end element terminals is obtained by removing
the mounting bolt, nut and spacer (see Figure 9, items 9, 16 and

18) and sliding the terminal end of the element assembly out of
the housing.

B. Center Elements

Access to the center mounted element terminals is obtained by
removing the terminal box cover.

6. END ELEMENT TERMINAL ASSEMBLY

Assemble end terminal, screw and wire as shown in Figure 5. Hold
terminal with pliers and tighten the terminal screw securely with a
screwdriver.

7. CENTER ELEMENT TERMINAL ASSEMBLY

Assemble center terminal, washers, nut and wire as shown in
Figure 6. Hold terminal with pliers and tighten the terminal nut
securely with a wrench.

CAUTION: Terminal clip is spot-welded to element terminal pin
and over-tightening terminal screw may break the weld or shear
off terminal pin. However, either the screw or nut should be suffi­ciently tightened to eliminate arcing.

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” (parallel­series) connection both shown in Figure 7. If heaters are connect­ed according to the “wrong” illustration, failure of any heater will
cause progressive failure of other heaters still operating.

9. DELTA CONNECTIONS — When heaters occur in multiples 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 8.

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 single-phase,
run only two conductors and follow the same rule.

3

WIRING

Wrong

Right

L1

L2

L2

L1

Radiant
Heaters

Wrong

Right

L1

L2

L2

L1

Radiant
Heaters

Figure 5 — End Element Terminal Assembly

Figure 7

Figure 8

Figure 6 — Center Element Terminal Assembly