Chromalox STAR-02A-81-P, STAR-02A-41-P, STAR-02A-61-P, STAR-05A-81-P, STAR-05A-21-P Installation, Operation And Renewal Parts Identification
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Chromalox
Type STAR Radiant Heater
For Portable Installations
© 2003 Chromalox, Inc.
Specifications – Table 1
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Amperage Dimensions (In.) Cord Ga./No. cond.
Model Figure Volts KW
1 Phase 3 Phase
BTU
A Height B Width D Depth 1 Phase 3 Phase
STAR-02A-11-PC 120 1.5 12.5 NA 5118
STAR-02A-81-P 208 2 9.6 NA 6824 14/3 NA
STAR-02A-21-P 1 240 2 8.3 NA 6824 28-1/2 11-3/8 11-3/4 14/3 NA
STAR-02A-71-P 277 2 7.2 NA 6824 14/3 NA
STAR-02A-41-P 480 2 4.2 NA 6824 14/3 NA
STAR-02A-61-P 600 2 3.3 NA 6824 14/3 NA
STAR-05A-81-P 208 4.5 21.6 NA 15354 12/3 NA
STAR-05A-21-P 240 4.5 18.8 NA 15354 12/3 NA
STAR-05A-71-P 2 277 4.5 15.9 NA 15354 49 11-3/8 11-3/4 14/3 NA
STAR-05A-41-P 480 4.5 9.4 NA 15354 14/3 NA
STAR-05A-61-P 600 4.5 7.5 NA 15354 14/3 NA
STAR-06A-83-P 208 6 28.8 16.7 20472 10/3 12/4
STAR-06A-23-P 240 6 25.0 14.4 20472 10/3 12/4
STAR-06A-71-P 3 277 6 21.7 — 20472 32-1/2 23-5/8 11-1/2 10/3 —
STAR-06A-43-P 480 6 12.5 7.2 20472 12/3 12/4
STAR-06A-63-P 600 6 10.0 5.8 20472 12/3 12/4
STAR-14A-83-P 208 13.5 NR 37.5 46062 NR 6/4
STAR-14A-23-P 240 13.5 NR 32.5 46062 NR 6/4
STAR-14A-71-P 4 277 13.3 47.7 — 45038 55-5/8 23-5/8 11-1/2 6/3 —
STAR-14A-43-P 480 13.5 28.1 16.2 46062 10/3 12/4
STAR-14A-63-P 600 13.5 22.5 13.0 46062 10/3 12/4
Figure 1 Figure 2
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Comes w/cord & plug
NA - Not Available
NR - Not Recommended
http://www.chromalox.com
®
DIVISION SECTION
REFERENCE
4
SALES
(Supersedes PG433)
(Supersedes )
VTS
PG433-1
161-304901-001
DATE
MAY, 2003
11-3/4
ide Vie
11-3/4
11-3/8
28-1/2
Front Vie
ide Vie
11-3/8
49
Front Vie
Page 2
IMPORTANT INSTRUCTIONS
When using electrical appliances, basic precautions should
always be followed to reduce risk of fire, electric shock and injury
to persons, including the following:
1. Read all instructions before using this heater.
2. This heater is hot when in use. To avoid burns, do not let bare
skin touch hot surfaces. Keep combustible materials, such as
furniture and papers at least 7 feet from the front of the heater.
3. Do not leave heater unattended while in operation.
4. Always disconnect heater when not in use.
5. Do not use outdoors in areas subject to wind.
6. Connect to properly grounded outlets or building ground.
7. This heater has hot surfaces. Do not use it in areas where gaso-
line, paint or flammable liquids are used or stored.
8. Use this heater only as described in this manual. Any other use
not recommended by the manufacturer may cause fire, electric
shock or injury to persons.
9. In order to prevent equipment damage, protect with a ground
fault device such as Chromalox STAR-TG series monitor.
10.
SAVE THESE INSTRUCTIONS
GENERAL
IMPORTANT:
SAVE THESE INSTRUCTIONS
FIRE HAZARD. Do not use as a residential or
household heater. Keep combustible material away
from heater. Do not operate heater where flammable vapors, gases or liquids are present.
To avoid personal injury read “IMPORTANT
INSTRUCTIONS” on this page before installation or
operation of heater.
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Figure 3 Figure 4
23-5/8"
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http://www.chromalox.com
11-1/2
11-1/2
ide Vie
23-5/8
Front Vie
32-1/2
ide Vie
55-5/8
Front Vie
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3
OPTIONAL ACCESSORIES
Chromalox ST AR series radiant heaters can be field modified by
adding optional kits. Refer to Chart Aand B to select the proper kit.
Disconnect Kit
The disconnect kit consists of a complete assembly consisting
of a disconnect switch (3 Pole), power terminal block and all hardware to complete the installation. This kit can be mounted to both
the fixed, overhead heater or the portable heater; see instruction
bulletin PG436 for details.
Cord Kits
Cord kits consist of 25 feet of 90°C cable and a right angle cord
fitting which can connect directly to the heater terminal box or disconnect switch (if used). See installation bulletin PF491 for details
Plugs
Single and three phase with ground. Available in nonlocking
and locking. See Chart B.
Tip Over and Ground Fault Kits
Star Tip Series Kit attaches to portable heater and de-energizes
the heater in the event it is tipped over.
Star-TG Series Kit combines the tip over and ground fault fea-
ture for portable heaters. See installation bulletin PG436.
WIRING
INSTRUCTIONS FOR FIELD CONVERSION FROM 3 PHASE TO 1 PHASE:
1. Remove nuts from all terminals.
2. Remove all pigtail leads and hat shaped buss bar.
3. Remove end of leadwire on terminal 5 and slip onto terminal 4.
4. Remove leadwire attached to instruction sheet and connect between terminals 4 and 6.
5. Install hat shaped buss bar between terminals 3 and 5.
6. Place pigtail lead marked “L1” on to terminal 2 and pigtail lead marked “L2” on to terminal 6.
7. Install nuts.
8. Connect entrance wiring to pigtail leads “L1” and “L2”. Connect ground to screw provided.
9. Inspect to make sure wiring is per “Single Phase Wiring” above.
ELECRIC 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 effectively grounded in accordance with the National Electrical Code, NFPA 70.
All electrical wiring must be done by a qualified
person in accordance with National Electrical Code
(NEC) and meet all state and local regulations.
1. Use heater only at the voltage specified on the nameplate.
2. The heater connection points are located in the gasketed termi-
nal enclosure. To remove cover, remove screw(s) on the cover.
Remove the cover to expose wiring connection points.
3. Agreen ground terminal is provided in the bottom of the enclo-
sure. The ground wire should be connected before other connections are made.
4. Use type "SO" or equal cord.
Refer to Table 1 for proper cord gage and number of conductors.
5. All 3 element heaters are factory pre-wired for 3-phase delta
operation. Some units can be converted to single phase operation
by changing the wiring. Refer to Table 1 for those heaters that
can be converted to single phase. The appropriate wiring diagram (Figure 4) is also located on the bottom of the enclosure.
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Chart A - Kit Selection
Disconnect Tipover Tipover Single Phase Three Phase
Model
Kit Kit w/Ground Fault Cord Set Cord Set
STAR-02A-11-PC NA NA NA
STAR-02A-81-P NA NA NA PCN 295670 NA
STAR-02A-21-P NA NA NA PCN 295670 NA
STAR-02A-71-P NA NA NA PCN 295670 NA
STAR-02A-41-P NA NA NA PCN 295670 NA
STAR-02A-61-P NA NA NA PCN 295670 NA
STAR-05A-81-P NA NA NA PCN 295662 NA
STAR-05A-21-P NA NA NA PCN 295662 NA
STAR-05A-71-P NA NA NA PCN 295670 NA
STAR-05A-41-P NA NA NA PCN 295670 NA
STAR-05A-61-P NA NA NA PCN 295670 NA
STAR-06A-83-P PCN 340662 PCN 340670 PCN 340726 PCN 295443 PCN 295435
STAR-06A-23-P PCN 340662 PCN 340689 PCN 340734 PCN 295443 PCN 295435
STAR-06A-71-P PCN 340662 PCN 340697 PCN 340742 PCN 295443 NA
STAR-06A-43-P PCN 340662 PCN 340700 PCN 340750 PCN 295662 PCN 295427
STAR-06A-63-P PCN 340662 PCN 340718 PCN 340769 PCN 295662 PCN 295427
STAR-1A4-83-P PCN 340662 PCN 340670 PCN 340726 NA PCN 295494
STAR-14A-23-P PCN 340662 PCN 340689 PCN 340734 NA PCN 295478
STAR-14A-71-P PCN 340662 PCN 340697 PCN 340742 PCN 295486 NA
STAR-14A-43-P PCN 340662 PCN 340700 PCN 340750 PCN 295443 PCN 295435
STAR-14A-63-P PCN 340662 PCN 340718 PCN 340769 PCN 295443 PCN 295427
Chart B - Plug Selection
OPTIONAL ACCESSORIES
Comes w/cord & plug
—
Fits Cable Dia. Plug Type Model Description Volts Amps Configuration NEMA # ANSI #
.385”-.780” Locking PGL-15-20 3 Pole, 4 Wire 250 20 L15-20 C73.85
.385”-.780” Locking PGL-15-30 3 Pole, 4 Wire 250 30 L15-30 C73.86
.595”-1.150” Locking PGL-16-30 3 Pole, 4 Wire 480 30 L16-30 C73.88
.595”-1.150” Locking PGL-17-30 3 Pole, 4 Wire 600 30 L17-30 C73.89
.750”-1.125” Locking PGL-3763C 2 Pole, 4 Wire 600 50 — —
.750”-1.125” Locking PGL-3764C 3 Pole, 4 Wire 600 50 — —
.625”-1.187” Non Locking PGN-6-50 2 Pole, 3 Wire 250 50 6-50 C73.53
.390”-.775” Non Locking PGN-15-20 3 Pole, 4 Wire 250 20 15-20 C73.59
.750”-1.250” Non Locking PGN-15-50 3 Pole, 4 Wire 250 50 15-50 C73.61
The above plugs are designed to be used with specific ranges of cable diameters. If not used with Chromalox Cable Kits, check cable manufacturers cable diameter to be sure plug fits selected cable.
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MAINTENANCE
ELECRIC SHOCK HAZARD. Disconnect all power
before servicing or replacing heating elements.
The reflectors should be kept clean to obtain the maximum
radiant output.
Element Replacement
1. Remove Terminal Box Cover.
2. Disconnect lead wires from heater terminals.
3. Remove safety grills (if installed).
4. Remove retainer screw located on the reflector at the terminal end.
5. Loosen (2), 3/8" nuts from the terminal box bracket located on
the back of the heater and slide the entire heating element
assembly out of the reflector assembly.
6. Remove wires and jumper straps as required to replace the
failed heating element(s).
7. Remove bulkhead fitting nuts and washers.
8. Remove failed element and replace with a new element.
Replace only with genuine Chromalox "Arctic End" elements. Use of other elements will cause excess temperatures
inside terminal box.
9. Place gasket on the bulkhead fitting and insert terminals and
fittings into the element holes in the terminal box.
10.Place washers and nuts on bulkhead fittings and tighten.
11. Replace wiring and jumper straps ( see Fig. 4).
12.Reassemble by following the reverse procedures (steps 5
through 1)
RENEWAL PARTS IDENTIFICATION
Element Housing Terminal Box
Model Element*** Reflector Safety Screen Gasket
STAR-02A-11-PC PCN 106059 PCN 111878 132-304879-004
STAR-02A-81-P
PCN 106067
PCN 111878 132-304879-004
STAR-06A-83-P PCN 340638 132-304879-003
STAR-02A-21-P
PCN 106075
PCN 111878 132-304879-004
STAR-06A-23-P PCN 340638 132-304879-003
STAR-02A-71-P
PCN 106083
234-891755-004 PCN 111878 132-304879-004
STAR-06A-71-P PCN 340638 132-304879-003
STAR-02A-41-P
PCN 106091
PCN 111878 132-304879-004
STAR-06A-43-P PCN 340638 132-304879-003
STAR-02A-61-P
PCN 106104
PCN 111878 132-304879-004
STAR-06A-63-P PCN 340638 132-304879-003
STAR-05A-81-P
PCN 106403
PCN 111894 132-304879-004
STAR-14A-83-P PCN 340857 132-304879-003
STAR-05A-21-P
PCN 106411
PCN 111894 132-304879-004
STAR-14A-23-P PCN 340857 132-304879-003
STAR-05A-71-P
PCN 106796
234-891-755-002 PCN 111894 132-304879-004
STAR-14A-71-P PCN 340857 132-304879-003
STAR-05A-41-P
PCN 106964
PCN 111894 132-304879-004
STAR-14A-43-P PCN 340857 132-304879-003
STAR-05A-61-P
PCN 106972
PCN 111894 132-304879-004
STAR-14A-63-P PCN 340857 132-304879-003
Parts Common to All Models:
Bulkhead fitting gasket . . . . . . . . . . . . . . 132-895735-008
Bulkhead fitting washer . . . . . . . . . . . . . . 328-890675-014
Bulkhead fitting nut . . . . . . . . . . . . . . . . . 200-890615-031
Element Support. . . . . . . . . . . . . . . . . . . . 291-304869-002
Vinyl Grip . . . . . . . . . . . . . . . . . . . . . . . . 024-304894-001
Parts Common to STAR, 06A-P and 14A-P Models:
Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . 333-557518-001
End Cap . . . . . . . . . . . . . . . . . . . . . . . . . . 039-510848-001
*** Includes element supports
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Page 6
TA- S3 - EF
Litho in U.S.A.
Chromalox warrants only that the Products and parts manufactured by Chromalox, when shipped, and the
work performed by Chromalox when performed, will meet all applicable specification and other specific
product and work requirements (including those of performance), if any, and will be free from defects in
material and workmanship under normal conditions of use. All claims for defective or nonconforming (both
hereinafter called defective) Products, parts or work under this warranty must be made in writing immediately upon discovery, and in any event, within one (1) year from delivery, provided, however all claims for
defective Products and parts must be made in writing no later than eighteen (18) months after shipment by
Chromalox. Defective and nonconforming items must be held for Chromalox’s inspections and returned to
the original f.o.b. point upon request. THE FOREGOING IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES WHATSOEVER, EXPRESS, IMPLIED AND STATUTORY, INCLUDING, WITHOUT LIMITATION, THE
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.
Notwithstanding the provisions of this WARRANTY AND LIMITATION Clause, it is specifically understood
that Products and parts not manufactured and work not performed by Chromalox are warranted only to the
extent and in the manner that the same are warranted to Chromalox by Chromalox’s vendors, and then only
to the extent that Chromalox is reasonably able to enforce such warranty, it being understood Chromalox
shall have no obligation to initiate litigation unless Buyer undertakes to pay all cost and expenses therefor,
including but not limited to attorney’s fees, and indemnifies Chromalox against any liability to Chromalox’s
vendors arising out of such litigation.
Upon Buyer’s submission of a claim as provided above and its substantiation, Chromalox shall at its
option either (i) repair or replace its Products, parts or work at the original f.o.b. point of delivery or (ii)
refund an equitable portion of the purchase price.
THE FOREGOING IS CHROMALOX’S ONLY OBLIGATION AND BUYER’S EXCLUSIVE REMEDY FOR
BREACH OF WARRANTY, AND IS BUYER’S EXCLUSIVE REMEDY AGAINST CHROMALOX FOR ALL CLAIMS
ARISING HEREUNDER OR RELATING HERETO WHETHER SUCH CLAIMS ARE BASED ON BREACH OF
CONTRACT, TORT (INCLUDING NEGLIGENCE AND STRICT LIABILITY) OR OTHER THEORIES, BUYER’S
FAILURE TO SUBMIT A CLAIM AS PROVIDED ABOVE SHALL SPECIFICALLY WAIVE ALL CLAIMS FOR
DAMAGES OR OTHER RELIEF, INCLUDING BUT NOT LIMITED TO CLAIMS BASED ON LATENT DEFECTS.
IN NO EVENT SHALL BUYER BE ENTITLED TO INCIDENTAL OR CONSEQUENTIAL DAMAGES AND BUYER
SHALL HOLD CHROMALOX HARMLESS THEREFROM. ANY ACTION BY BUYER ARISING HEREUNDER OR
RELATING HERETO, WHETHER BASED ON BREACH OF CONTRACT, TORT (INCLUDING NEGLIGENCE AND
STRICT LIABILITY) OR OTHER THEORIES, MUST BE COMMENCED WITHIN ONE (1) YEAR AFTER THE
DATE OF SHIPMENT OR IT SHALL BE BARRED.
W2008M
WARRANTY AND LIMITATION OF REMEDY AND LIABILITY
http://www.chromalox.com
2150 N. RULON WHITE BLVD., OGDEN, UT 84404
Phone: 1-800-368-2493 www.chromalox.com
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