Precision Control Systems 4069 User Manual

Model 4069 User’s Manual

Publication #: A106828-001 Rev. 3

January 2009

Another quality product from:

7128 Shady Oak Road, Eden Prairie, MN 55344

Phone: [phone] Fax: [phone]

E-mail: [email protected]

www.researchinc.com

Copyright © 2003 by Research, Inc. All rights re ser ved . U nder copyright laws, neither the documentati on
nor the software may be copied, photocopied, reproduced, translated, or reduced to any electronic medium
or machine-readable form, in whole or in part, without the prior written consent of Research, Inc., except in
the manner described in the documentation.

Research, Inc. reserves the right, without notice, to alter or improve the designs or specifications of the
products described herein. No warranty or guarantee of any kind is expressed or implied by information
contained herein.

Printed in the U.S.A.

Dear Valued Customer:

Thank you for purchasing a Model 4069 ChambIR

®

infrared heater. We believe it is the finest

heating system of its type and are confident you will think so also.

This instruction manual has been carefully prepared to ensure you will be able to easily install
and operate the Model 4069 heater and to fully realize all its inherent capabilities. We invite your
comments as well as any issues you may have regarding this manual or the Model 4069.

Requirement

Appropriate Contact

Additional information regarding application Your local sales representative.
of the Model 4069 heater or other Research Inc.
products.

Ordering additional Research Inc. products or Manuals. Your local sales representative

or Research, Inc. Customer
Service [phone]

Technical assistance and training. Research Inc. Factory Service
[phone]

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.

Table of Contents

Section 1 – Introduction.......................................................................................... 1-1

Section 2 – Features & Benefits.............................................................................. 2-1

Section 3 – Specifications........................................................................................ 3-1

Dimensions............................................................................................................. 3-2

Ordering Information.............................................................................................. 3-3

Accessories, Spare & Replacement Parts............................................................... 3-4

Section 4 – Safety..................................................................................................... 4-1

Section 5 – Installation…………………………………………….……………... 5-1

5.1 Un-pack and Check for Damage.......... ..................... ..................... ................... 5-1

5.2 Mounting the Heater......................................................................................... 5-1

5.3 Gas Struts...................................................................................................... ... 5-1

5.4 Heater Cooling Connections............................................................................. 5-2

5.5 Electrical Connections...................................................................................... 5-4

Section 6 – Maintenance......................................................................................... 6-1

6.1 Lamp Removal/Replacement/Installation......................................................... 6-1

6.2 Split Quartz Liner Cleaning and Replacement.................................................. 6-3

6.3 Cleaning the Reflectors..................................................................................... 6-5

Section 7 – Spare & Replacement Parts................................................................ 7-1

Appendix................................................................................................................... A-1

Section 1 – INTRODUCTION

The Model 4069 ChambIR® infrared chamber heater is designed for use in any
application that requires a high-intensity, clean, responsive, non-contact heat source.
This heater can be used for both continuous processes and test specimens.

Typical applications for the Model 4069 include:

Curing silicone tubing
Re-glossing rubber and plastic tubing
Skin cure automotive hoses and tubing
Burning lubricant off of extruded wire
Preheating metal parts prior to rubber or plastic coating
Curing coatings or adhesives on wire or cable

The Model 4069 includes the following major components:

Heater Module – The heater has highly polished aluminum reflectors that direct the
infrared energy generated by ceramic end-seal ‘T-3 style’ quartz halogen lamps, which
are factory-installed in the heater. Heated lengths of 10, 16, 25, and 38 inches (254, 406,
635, and 965 mm) are offered for the Model 4069. Additional lamps can be ordered
separately from the heater.

1-1

Water Cooling – 90° F or less cooling water is required during operation of the Model

4069. Flexible tubing and plumbing fittings are supplied with each heater for easy
installation. Required cooling-water flow rates are listed in Specifications. Chilled water
below 50° F is not required or desired due to possible condensation on reflectors.

Air Cooling – A cooling fan is designed into the Model 4069 housing and provides
ambient airflow through the heater body. This airflow helps to prevent air-borne process
gasses from depositing on the reflector surfaces. It also provides cooling to the quartz
halogen lamp end seals.

Electrical Cable – The Model 4069 heater is electrically wired from the T3 lamps to
intermediate terminal blocks within the heater. Two 12-foot (2.4 m) electrical cables are
supplied with each heater.

Split Quartz Liner – A split quartz liner is included with the Model 4069 and provides
contamination protection for the aluminum reflectors. When installed in the heater, the
quartz window protects the aluminum reflector and lamp from contaminants released in
the heating process, resulting in maximum efficiency of the heater.

Optional Power Control System – The Model 4069 can be ordered with the ‘PC’
option. An electrical junction box is included and wired directly to the Model 935
ControlIR power control box with 15 feet (4.6 m) of electrical cable. The heater is
supplied with two 12-foot (3.7 m) electrical cables and terminated with connectors that
plug into the junction box. Please see Figure 5-4, Typical Installation, as well as the
Model 935 ControlIR® product data sheet for further detail.

Figure 1-1. Model 4069 with PC Option

1-2

Section 2 – FEATURES & BENEFITS

The design and functionality of the Model 4069 supplies a variety of features and related
benefits:

Rapid Response – The quartz halogen lamps heat up and cool down instantly in response
to power control signals. They reach 90 percent of full operating temperature within three
seconds of a cold start. The radiant energy dissipates to ten percent five seconds after the
power supply is disconnected.

Continuous Operation – The formed steel and extruded aluminum construction of the
Model 4069, combined with the liquid- and air-cooling, allows the heater to withstand
continuous high-temperature operation.

Controllable Energy Output – The infrared energy emitted from the heater can be
adjusted to match the heating requirements of a variety of applications.

The Model 4069 ordered with the ‘PC’ (power control) option is a complete heating
solution designed with a number of features including heater on/off control switching,
potentiometer local control, and mechanically interlocked doors with main-power
disconnect switch. Heater over-temperature indicators and system cooling on/off control
switches, with indicator lamps, are also included. Lamp out indication circuitry is also
designed into the system, along with the user's choice of either a digital voltmeter or
digital temperature indicator.

In addition, each Model 4069 heater is wired with zoning capability. Please contact
Research, Inc. for more details regarding the Model 965 ControlIR power control cabinet
with zoning options. Customized controls are also available. Please contact Research
Inc. to discuss the requirements.

2-1

Section 3 - SPECIFICATIONS

Model Number*

Inches (mm)

Lamp Wattage

Lamp Lighted Length,

Lamp Type

(LPM)

Lamp Part Number

Wattage Heater, kW

Lamp Rated Voltage

***Water Flow GPM

Heater @ Required

Water Flow, psi +/- 5psi

Pressure Drop Through

(kg)

Total Weight, Pounds

4069-12R-10L-12kW-240V 10 (254) 1000 QIH240-1000RI2 103390-003 240 12.0 1.2 (4.5) 10 85 (39)
4069-12R-10L-12kW-480V 10 (254) 1000 QIH240-1000RI2 103390-003 240 12.0 1.2 (4.5) 10 85 (39)
4069-12R-10L-24kW-240V 10 (254) 2000 QIH240-2000RI2 103390-004 240 24.0 2.3 (8.6) 22 85 (39)
4069-12R-10L-24kW-480V 10 (254) 2000 QIH240-2000RI2 103390-004 240 24.0 2.3 (8.6) 22 85 (39)
4069-12R-16L-19kW-240V 16 (406) 1600 QIH240-1600RI2 103390-005 240 19.2 1.8 (6.9) 16 95 (43)
4069-12R-16L-19kW-480V 16 (406) 1600 QIH240-1600RI2 103390-005 240 19.2 1.8 (6.9) 16 95 (43)
4069-12R-25L-30kW-480V 25 (635) 2500 QIH480-2500RI2 103390-007 480 30.0 1.4 (5.3)** 31 124 (56)
4069-12R-38L-46kW-480V 38 (965) 3800 QIH480-3800RI2 103390-010 480 45.6 2.1 (8.0)** 63 155 (70)
4069-18R-10L-18kW-240V 10 (254) 1000 QIH240-1000RI2 103390-003 240 18.0 1.7 (6.5) 15 112 (51)
4069-18R-10L-18kW-480V 10 (254) 1000 QIH240-1000RI2 103390-003 240 18.0 1.7 (6.5) 15 112 (51)
4069-18R-10L-36kW-480V 10 (254) 2000 QIH240-2000RI2 103390-004 240 36.0 3.3 (12.7) 42 112 (51)
4069-18R-16L-29kW-240V 16 (406) 1600 QIH240-1600RI2 103390-005 240 28.8 2.7 (10.2) 29 140 (64)
4069-18R-16L-29kW-480V 16 (406) 1600 QIH240-1600RI2 103390-005 240 28.8 2.7 (10.2) 29 140 (64)
4069-18R-25L-45kW-480V 25 (635) 2500 QIH480-2500RI2 103390-007 480 45.0 2.1 (7.9)** 61 177 (80)
4069-18R-38L-68kW-480V 38 (965) 3800 QIH480-3800RI2 103390-010 480 68.4 3.1 (11.9)** 37 228 (104)

* Recommended maximum product diameter of 12-reflector models is two inches. Recommended maximum product diameter of 18-reflector model is

four inches.

** Stated flow rates are for each of two flow paths
*** Maximum inlet-water temperature not to exceed 100°F (37°C)

3-1

Model Number

Overall Dimensions, Inches (mm)

A B C D E

∅F**

Mounting Dimension,

Inches (mm)

J K L

4069-12R-10L-XX-XX

4069-12R-16L-XX-XX

4069-12R-25L-XX-XX

4069-12R-38L-XX-XX

4069-18R-10L-XX-XX

4069-18R-16L-XX-XX

4069-18R-25L-XX-XX

4069-18R-38L-XX-XX

* Fully opened angle = 40 degrees
** Recommended maximum product diamet er of 12-reflector models is two inches. Recommended maximum
product diameter of 18-reflector models is four inches.

18.82
(478)

24.44
(621)

33.44
(849)

46.44

(1180)

18.27
(464)

23.89
(607)

32.89
(835)

45.89

(1166)

16.13
(410)

21.75
(552)

30.75
(781)

43.75

(1111)

16.13
(410)

21.75
(552)

30.75
(781)

43.75

(1111)

14.5

(368)

14.5

(368)

14.5

(368)

14.5

(368)

17.0

(432)

17.0

(432)

17.0

(432)

17.0

(432)

15.63
(397)

15.63
(397)

15.63
(397)

15.63
(397)

18.55
(471)

18.55
(471)

18.55
(471)

18.55
(471)

17.11
(435)

17.11
(435)

17.11
(435)

17.11
(435)

20.61
(523)

20.61
(523)

20.61
(523)

20.61
(523)

3.22
(82)

3.22
(82)

3.22
(82)

3.22
(82)

5.90

(150)

5.90

(150)

5.90

(150)

5.90

(150)

4.88

(124)

4.88

(124)

4.88

(124)

4.88

(124)

6.06

(154)

6.06

(154)

6.06

(154)

6.06

(154)

13.00
(330)

18.62
(473)

27.62
(702)

40.62

(1032)

13.00
(330)

18.62
(473)

27.62
(702)

40.62

(1032)

M10

Figure 3-1. Dimensions

3-2

Ordering Information

Model Product Description

4069 Parabolic Clamshell Heating System (Includes lamps and split-quartz liner)

Code Reflector Number

12R
18R

Code Length, Heater Power Rating, Voltage

12 Reflectors (Maximum product diameter up to 2 inches)
18 Reflectors (Maximum product diameter up to 4 inches)

10L-12KW-240V
10L-12KW-480V

10L-24KW-240V*

10L-24KW-480V
16L-19KW-240V

16L-19KW-480V

38L-46KW-480V*

25L-30KW-480V

10L-18KW-240V
10L-18KW-480V

10L-36KW-480V

16L-29KW-240V*

16L-29kW-480V
25L-45KW-480V*
38L-68KW-480V*

12 Reflector Size Availability:

10-inch length, 12 Kilowatts, 240 Volts
10-inch length, 12 Kilowatts, 480 Volts

10-inch length, 24 Kilowatts, 240 Volts
10-inch length, 24 Kilowatts, 480 Volts

16-inch length, 19 Kilowatts, 240 Volts
16-inch length, 19 Kilowatts, 480 Volts

25-inch length, 30 Kilowatts, 480 Volts
38-inch length, 46 Kilowatts, 480 Volts

18 Reflector Size Availability:

10-inch length, 18 Kilowatts, 240 Volts
10-inch length, 18 Kilowatts, 480 Volts

10-inch length, 36 Kilowatts, 480 Volts
16-inch length, 29 Kilowatts, 240 Volts

16-inch length, 29 Kilowatts, 480 Volts
25-inch length, 45 Kilowatts, 480 Volts
38-inch length, 68 Kilowatts, 480 Volts

Code Optional Power Control System

PC-VM

PC-TI

Model 4069 heater supplied with Model 935 power control system. Includes: electrical junction box,
interface wiring, lamp-out detection, and a choice of digital voltmeter or digital temperature indicator.

Power Control System with Digital Volt Meter – 50 Amp Rating
Power Control System with Digital Volt Meter – 80 Amp Rating (*)

Power Control System with Digital Temperature Indicator – 50 Amp Rating
Power Control System with Digital Temperature Indicator – 80 Amp Rating (*)

* These models exceed a 50-amp rating, requiring an 80-amp rated power controller

Ordering Example

Model Reflector Number

Typical Model Number 4069 18R 25L-45KW-480V PC-TI

Length, Heater Power

Rating, Voltage

Optional Power
Control System

3-3

Accessories, Spare, and Replacement Parts – Model 4069

Model Description

103390-003
103390-004
103390-005
103390-007
103390-010

106721-001
106721-002
106721-003
106721-004

106778-001
106778-002

106895-001
106895-002
106895-003
106895-004

106895-005
106895-006
106895-007
106895-008

M4069

Replacement Lamp For:

12kW or 18kW maximum-power rated heater (10 inch length, 1000-watts)
24kW or 36kW maximum-power rated heater (10 inch length, 2000-watts)
19kW or 29kW maximum-power rated heater (16 inch length, 1600-watts)
30kW or 45kW maximum-power rated heater (25 inch length, 2500-watts)
46kW or 68kW maximum-power rated heater (38 inch length, 3800-watts)

Replacement Reflector For:

10-inch length
16-inch length
25-inch length
38-inch length

Replacement End Reflectors (Four required per heater) for:

12-reflector size heater
18-reflector size heater

Spare Split Quartz Liner Half (Two required per heater) for:

12-reflector, 10-inch length
12-reflector, 16-inch length
12-reflector, 25-inch length
12-reflector, 38-inch length

18-reflector, 10-inch length
18-reflector, 16-inch length
18-reflector, 25-inch length
18-reflector, 38-inch length

Additional Operation Manual

3-4

Section 4 – SAFETY
GENERAL: The Model 4069 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, read the
instructions in this instruction manual and follow these safety practices to help prevent
accident or injury.

LATCHING SAFETY LATCH

A latching shock is installed on the left side of the model 4069 heater. The latch will
prevent the heater from closing should the gas strut fail. When closing the heater pull the
knob to release the latch while closing.

INFRARED RADIATION - CAUTION! Continuous exposure to high-intensity
infrared radiation at close proximity could be harmful to eyes or skin. Although infrared
lamps emit negligible ultra violet electromagnetic radiation, harmful burns can 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 eyes be shielded from the glare if observing the lamps 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, reflector, or metal parts near the lamps may cause severe burns.

WARNING!

NEVER place hands under or in front of the heating elements.

ALWAYS allow heating element to cool at least three minutes before touching the lamps
or adjacent parts.

ELECTRICAL SAFETY: There is danger of electrical shock when servicing the heater.

CAUTION! Observe all applicable local and national electrical codes and ensure that a

safe electrical ground system is installed before attempting to operate the heater. Refer to
the Section 5 for proper installation procedures.

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 end covers removed.

4-1

FIRE SAFETY:

1. Obey the same fire-safety rules you observe when working with hot plates,

propane or acetylene torches, soldering irons, and other equipment that operates at
extremely high heat.

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 fire from all the types of material near the heater.

Section 5 – INSTALLATION

5.1 UNPACK AND CHECK FOR DAMAGE: Remove the Model 4069 heater

from its shipping container and associated packaging. Check the unit for any potential
damage due to shipping. In the unlikely event damage has occurred, keep all shipping
containers and materials in order to file a damage claim with the shipping company
responsible for shipping the unit.

5.2 MOUNTING THE HEATER: The Model 4069 heater should be mounted to a
structure or framework that is designed to support the weight of the heater and provide
stability to the unit. There are four M10 threaded holes on each side of the heater for
mounting. Mount the heater in an orientation that will allow for the heater to be fully
opened (40º maximum) for maintenance, as well as for ease of threading product in
continuous process applications. Please refer to Figure 3-1 for product dimensions and
mounting information.

In vertical applications, the right side of the heater should be on top for the flow
switch to operate correctly.

Note: Vertical burn lamps are recommended when operating the Model 4069 in a
vertical orientation. All Research Inc. lamps associated with the Model 4069 heater are
designed for universal (both horizontal and vertical) operation.

5.3 GAS STRUTS: The Model 4069 includes gas struts to assist in opening the
Model 4069 heater. The struts also limit the angle to which the heater can be opened to
40 degrees.

Note: If the heater is used in a vertical operation Gas Struts are not required. A Stop
bolt is added to the hinge to limit the opening of the heater. If the heater is relocated to a
vertical operation remove one strut, preferably the top strut. The latching strut may be
replaced with the non-latching strut if applicable.

If replacing the struts, orient such that the shafts extend to the bottom of the heater (see
Figure 5-1).

NOTE: FOR SAFETY, a latching shock is installed on the left side of the model 4069
heater. The latch will prevent the heater from closing should the gas strut fail.
To Use: When closing the heater, pull the knob to release the latch while closing.

4-2

Figure 5-1. Gas Strut Orientation

Figure 5-2. Gas Strut Pin Figure 5-3. Gas Strut Pin Removal

5.4 HEATER COOLING CONNECTIONS: The highly polished aluminum

reflectors require liquid cooling to keep the reflecting surface from overheating. If the
reflectors overheat, the surface can become oxidized. When oxidation occurs, the
aluminum begins to absorb the energy from the lamps, rather than reflecting it to the
product, reducing the efficiency of the heater.

Each Model 4069 is designed with ‘quick-disconnect’ fittings protruding from the heater
cover. There is one inlet and one outlet sized for ½ inch O.D. Nylon 11 flexible tubing
(included with heater). Please refer to Specifications for proper water-cooling flow rates.

It is recommended to cool the Model 4069 using a closed-loop cooling system that is
sized properly for the size of the heater. The recommended cooling media is clean, de­ionized, or distilled water. A water/glycol solution may also be used if required by the
closed loop cooling system.

Figure 5-4 details a typical installation for the Model 4069 heater.

5-1

Figure 5-4. Typical Installation

5-2

5.5 ELECTRICAL CONNECTIONS: The Model 4069 is supplied with two 12­foot (254 mm) power cable bundles. The cable bundles consist of the power wires for the
lamps and fan, as well as control wires for the thermostat (TSTAT), water flow interlock
switch (WFIS), and heater open interlock switch (HILS). If the Model 4069 was ordered
without the "PC" option, the wires are not terminated into a connector. It is the
customer's responsibility to hard wire the heater into the power control system. Wiring
diagrams can be found in the Appendix.

Note: The heater should never be directly wired into a voltage source. The heater should
always be wired into a power controlling system.

Model Number

4069-12R-10L-12kW-240V-PC-XX
4069-12R-10L-12kW-480V-PC-XX

4069-12R-10L-24kW-240V-PC-XX

4069-12R-10L-24kW-480V-PC-XX
4069-12R-16L-19kW-240V-PC-XX
4069-12R-16L-19kW-480V-PC-XX
4069-12R-25L-30kW-480V-PC-XX
4069-12R-38L-46kW-480V-PC-XX
4069-18R-10L-18kW-240V-PC-XX
4069-18R-10L-18kW-480V-PC-XX
4069-18R-10L-36kW-480V-PC-XX
4069-18R-16L-29kW-240V-PC-XX
4069-18R-16L-29kW-480V-PC-XX
4069-18R-25L-45kW-480V-PC-XX
4069-18R-38L-68kW-480V-PC-XX

System Voltage

(3 phase)

240
480
240
480
240
480
480
480
240
480
480
240
480
480
480

System

Amperage

29
15
58
29
47
24
37
55
44
22
43
70
35
55
83

-

THERMOSTAT (TSTAT): The Model 4069 is supplied with a thermostat (TSTAT) to

protect from overheating. The TSTAT protects the heater from overheating only if the
TSTAT is properly wired into the control interlock of the power control system. The
TSTAT should be wired into a disconnect relay of the power controller/system. If the
TSTAT "open" (trips), the disconnect relay of the power control system should remove
power to the Model 4609 Heater. The TSTAT is mounted to the backside of the last
reflector before the cooling fluid exits the heater. The TSTAT has a fixed trip
temperature of 160ºF. If the reflector reaches 160ºF, the TSTAT will "open" and will not
"close" (reset) until it cools down to 130ºF.

WATER FLOW SWITCH (WFIS): Water-cooling is required for proper and safe
operation of the Model 4069. The heater is supplied with a Water Flow Interlock Switch
(WFIS) to ensure that it has water-cooling going through the reflectors, to protect from
overheating. The WFIS protects the heater from overheating only if the WFIS is properly
wired into the control interlock of the power control system. The WFIS should be wired

5-3

into a disconnect relay of the power controller/system. If the WFIS "opens" (trips), the
disconnect relay of the power control system should remove power to the heater. The
WFIS is plumbed inline with the cooling line of the last reflector, before the cooling fluid
exits the heater. The WFIS has a minimum flow-rate requirement of 0.5 GPM. If the
liquid cooling flow rate falls below 0.5 GPM, the WFIS will "open", and will not "close"
if the cooling system fails to provide the minimum 0.5 GPM of cooling fluid. The WFIS
is designed to protect the heater if there is a malfunction in the cooling supply. Please
refer to Specifications for proper water-cooling rates.

Note: Flow switch is packaged internal in all but the 10-inch length models. In this case,
it is shipped separately.

HEATER "OPEN" INTERLOCK SWITCH (HILS): It is very dangerous to open the
Model 4069 while it is in operation. The heater is supplied with a Heater "Open"
Interlock Switch (HILS). The HILS is to protect an operator from the lamps of the
heater, if the operator happens to open the heater while it is in operation. The HILS
protects the operator only if the HILS is properly wired into the control interlock of the
power control system. The HILS should be wired into a disconnect relay of the power
controller/system. The HILS is a dry-contact switch mounted in the heater where the two
heater halves meet. If the heater is opened while the lamps are on, or if the lamps are in a
standby mode, the HILS will "open" (trip), not allowing the lamps to turn on. If the
HILS "opens", the disconnect relay of the power control system should remove power to
the lamps of the heater.

UNITS ORDERED WITH THE "PC" OPTION: Each Model 4069 is supplied with
two 12-foot electrical cables. When the heater is ordered with the "PC" option, the
electrical cable is terminated with a connector that plugs into a junction box. The
junction box is wired directly into the power control box with 15 feet (4.6 m) of electrical
cable. See the appendix section for electrical connections for the junction box.

5-4

Section 6 – MAINTENANCE

The repair and maintenance of the Model 4069 includes replacement of the T3-style
lamps, cleaning/replacement of the split quartz liner, and cleaning of the reflectors.

6.1 LAMP REMOVAL/REPLACEMENT/INSTALLATION: The T3-style lamps
are installed into the Model 4069 when shipped from the factory. The following
procedure details the process to replace the lamps in the Model 4069 (reference Figure 6­1, 6-2, & 6-3):

Note:

• Remove all power from the heater BEFORE attempting to install/replace the

lamps.

• Allow a minimum of ½-inch (12 mm) of slack in the lamp leads so that th e leads

are not taut when inserted into the lamp terminal blocks.

• Always take care to handle all lamps by the ceramic end seals and use clean

cotton or latex gloves to prevent contamination of the quartz lamp envelopes.

1. Remove quartz liner (see Section 6.2). Take this opportunity to clean the liner.

2. Remove end-cover screws (4 per end cover).

3. Remove end covers on both ends of the heater.

4. Remove end-reflector screws (2 per reflector)

5. Remove end reflectors on both ends.

6. Remove the lamp wires from the ceramic terminal blocks.

7. Carefully disengage lamp from clips (both ends).

8. Slide the end of the lamp through the rectangular cutout in the end casting on one

end of the heater through the rectangular cutout in the end casting of the other end
of the heater.
Installing new lamp

9. Position the lamp over the lamp clips so that the lighted portion of the lamp is

equally space in the reflector.

Note: Be sure that the Gas Fill Tip is facing away from the reflector

10. While holding the lamp on both ends by the ceramic end seals, with light pressure

push the lamp into the lamp clips. A slight twisting motion of the lamp, while
pushing the lamp into the clip, helps the lamp to seat properly.

6-1

Figure 6-1. Lamp Installation

11. Cut wire to a length allowing for a service loop.

12. Strip back the insulation on the end of the lamp leads approximately 1-1/2 inches

(38 mm).

13. Insert the bare wire of each insulated lamp lead into the ceramic terminal block

position that previously held the old lamp. Push each lead wire into the terminal
block far enough so, that when tightened, the setscrew will hold the lead securely.

14. Tighten the setscrews in each terminal block so the lead wires are held securely

(1.0 Ft.-Lbs. [1.4 N-m]).

15. Form a loop within each lead along its length. This loop will act as a strain relief

within the lead during normal operation of the heater.

16. Reinstall the end reflectors, end covers, and quartz liner.

6-2

6.2 Split Quartz Liner Cleaning and Replacement: The split quartz liner can be
replaced or removed from the Model 4069 for periodic cleaning. Use the following
procedure to remove/reinstall/clean the quartz liner:

Note:

• Remove all power from the heater BEFORE attempting to install/replace the

lamps.

• Always use clean cotton or latex gloves when handling the split quartz liner so

as not to deposit any oils or grease from your hands onto the surface of the split
quartz liner.

1. Open the Model 4069 Heater to allow access to each heater half for split quartz

liner installation.

2. Loosen the screws of one liner bracket and slide the bracket away from the

quartz-liner of one liner half at one end of the heater, while supporting the liner
with other hand.

Figures 6-2 & 6-3. Quartz-Liner Bracket Removal

3. Remove the bracket from the end casting of the heater.

4. Gently slide the quartz liner out of the grooves of the liner bracket from the

opposite end. Take care so that the quartz liner does chip or crack as it is
removed.

6-3

Figure 6-4. Quartz Liner Removal

5. If cleaning the liner, use a non-abrasive glass cleaner (i.e. household ammonia

and water or isopropyl alcohol) and a clean, dry, lint-free cloth. After cleaning, do
not touch the outside surface of the liner unless wearing cotton gloves.

6. Reinsert the edges of the liner into the grooves of the quartz-liner bracket.

7. Reinstall the other bracket and secure with the two bracket screws.

8. Repeat this process for the other half of the liner.

6.3 Cleaning the Reflectors: Clean reflectors provide the greatest radiant efficiency.
If the reflector surface becomes contaminated, it reflects less energy. The energy that is
not reflected is lost, absorbed by the reflectors, and removed by the cooling water and air.

The following procedure should be used to clean the Model 4069 reflectors:

Note:

• Remove all power from the heater BEFORE attempting to clean the heater

reflectors.

1. Remove the lamps and quartz liner as described in Section 6.1 – Lamp

Removal/Replacement/Installation and Section 6.2 Split Quartz Liner Cleaning
and Replacement.

2. Clean the reflectors with a mixture of warm water and common household

ammonia followed by a thorough wipe-down using a clean, water-dampened
flannel cloth.

3. Depending on the type of contamination present on the reflector, a suitable

solvent may be required to remove the contamination. The solvent must be
selected based on its inability to adversely affect the aluminum reflector.

4. Thoroughly wipe the reflector using the warm water/household ammonia mixture

followed by the dampened flannel cloth.

5. Replace the lamps and quartz liner, as outlined in Section 6.1 – Lamp

Removal/Replacement/Installation and Section 6.2 Split Quartz Liner Cleaning
and Replacement.

If necessary, the reflectors may require re-polishing. This is permissible because the
reflector is solid aluminum and can be re-polished many times without damage from

6-4

continued erosion. A fine particle polishing compound, such as a chrome, semi-chrome,
or soft metal polishing compound may be used. These types of compounds can be found
at a local automotive or metal-polishing supply house. Follow the polishing instructions
listed on the polishing product.

The reflectors can be removed from the Model 4069 Heater to make cleaning and
maintenance easier. The following procedure should be used to remove the Model 4069
reflectors:

Note:

• Remove all power from the heater BEFORE attempting to install/replace the

heater reflectors.

1. Drain all cooling fluid from the heater and blow out the heater cooling lines with

compressed air.

2. Remove the heater-cover screws and heater cover.

Figure 6-5. Heater Cover Removal

3. Disconnect the cooling line from the reflector to be maintained.

4. Loosen all screw from all reflectors on one side of the end casting of the reflector

to be maintained.

6-5

5. Remove the reflector mounting screws from the end casting of the reflector to be

maintained.

6. Remove the reflector.

Figure 6-6. Reflector Removal

6-6

Section 7 – SPARE & REPLACEMENT PARTS

Replacement parts for the Model 4069 are listed below. Reference Figures 7-1 through
7-6 when using this list.

Figure 7-1.

Figure 7-2. Figure 7-3.

7-1

Figure 7-4. Figure 7-5.

Figure 7-6.

7-2

Table 7-1. Parts List for Model 4069

12 Reflector 18 Reflector

Item Part Number Description 10L 16L 25L 38L 10L 16L 25L 38L

1 054979-077 Screw, Panhead 8-32x5/16 Sst Ph 8 8 8 8 8 8 8 8
2 054979-086 Screw, Panhead 8-32x2-1/4 Sst Ph 4 4 4 4 4 4 4 4
3 054979-097 Screw, Panhead 8-32x3/8 Ph Sems Int 44 44 44 44 44 44 44 44
4 054982-005 Nut-Kep 10-32 Nc Zinc 2 2 2 2 2 2 2 2
5 055000-009 Screw-Sm Ph6-32x1/4t23 Cad Ph 6 6 6 6 6 6 6 6
6 055020-082 Screw, Flathead 8-32x3/4 Sst Ph(82) 2 2 2 2 2 2 2 2
7 055029-048 Washer-Flat,.39idx.625x.057,Ss 4 4 4 4 4 4 4 4
8 055296-064 Screw-Socket 1/4-20x1/2,Sst 12 12 12 12 12 12 12 12

9 055452-003 Nut-Hex Nylock 5/16-18 2 2 2 2 2 2 2 2
10 055959-000 Switch-Leaf Act Spdt H/S 1 1 1 1 1 1 1 1
11 057885-001 Plug-Pipe,1" Npt 2 2 2 2 2 2 2 2
12 064704-009 Screw-Shoulder .375x2.50 Skt Hd 2 2 2 2 2 2 2 2
14 100441-001 Handle-Stainless Stl,5.359 1 1 1 1 1 1 1 1

15** 102423-001 Ball End Socket 4 4 4 4 4 4 4 4

18 106090-001 Bracket-Angle Ball Stud,10mm 4 4 4 4 4 4 4 4
19 106647-001 Bracket Switch,M4069 1 1 1 1 1 1 1 1
20 106648-001 Bracket Switch Actuator,M4069 1 1 1 1 1 1 1 1
21 106782-001 Latch-Draw,5in,700lb 2 2 2 2 2 2 2 2

23** 106793-001 Gas Strut Shield , 2"X6"L 2 2 2 2 2 2 2 2

50 054979-041 Screw, Panhead 6-32x3/16 Sst Ph 50 50 50 50 74 74 74 74
51 054979-082 Screw, Panhead 8-32x1 Sst Ph 12 12 12 12 20 20 20 20
52 054979-112 Screw, Panhead 10-32x1 Sst Ph 48 48 48 48 72 72 72 72
57 099653-001 Thermostat Assembly 1 1 2 2 1 1 2 2

58*** 099655-001 Flow Switch 1 1 2 2 1 1 2 2

59 100571-003 Terminal Block Ceramic 2p 30a 12 12 12 12 18 18 18 18
60 103884-001 Lamp Spring Clip 24 24 24 24 36 36 36 36
61 104358-001 Fitting-Elbow,3/8 NPT,1/2 inch Tube 24 24 24 24 36 36 36 36

62*** 104399-002 Fitting-Str,1/2 inch tube,1/2 NPT,Female 2 2 4 4 2 2 4 4

63 104431-002 Nylon Tubing -1/2 inch OD 17 23 32 45 22 31 44 64
64 106789-003 Fitting-Bulkhead,Elbow,1/2 inch tube 2 2 4 4 2 2 4 4

106895-001 Split Quartz Liner for 4069-12-10 2
106895-002 Split Quartz Liner for 4069-12-16 2
106895-003 Split Quartz Liner for 4069-12-25 2

65

66

67

68

69

70

106895-004 Split Quartz Liner for 4069-12-38 2
106895-005 Split Quartz Liner for 4069-18-10 2
106895-006 Split Quartz Liner for 4069-18-16 2
106895-007 Split Quartz Liner for 4069-18-25 2
106895-008 Split Quartz Liner for 4069-18-38 2
103345-002 End Cover for 4069-12-XX 4 4 4 4
103345-003 End Cover for 4069-18-XX 4 4 4 4
103390-003 Lamp - 1000W, 240V, Ceramic Endseal 12* 18*
103390-004 Lamp - 2000W, 240V, Ceramic Endseal 12* 18*
103390-005 Lamp - 1600W, 240V, Ceramic Endseal 12* 18
103390-007 Lamp - 2500W, 480V, Ceramic Endseal 12 18
103390-010 Lamp - 3800W, 480V, Ceramic Endseal 12 18
106850-001 Quartz Window Clip for 4069-12-XX 4 4 4 4

106850-002 Quartz Window Clip for 4069-18-XX 4 4 4 4
106721-001-A Reflector for 4069-XX-10 12 18
106721-002-A Reflector for 4069-XX-16 12 18
106721-003-A Reflector for 4069-XX-25 12 18
106721-004-A Reflector for 4069-XX-38 12 18

106776-001 Machined End Cast,A for 4069-12-XX 2 2 2 2

106776-002 Machined End Cast,A for 4069-18-XX 2 2 2 2

7-3

71 106777-001 Machined End Cast,B for 4069-12-XX 2 2 2 2

106777-002 Machined End Cast,B for 4069-18-XX 2 2 2 2

72 106778-001 End Reflector for 4069-12-XX 4 4 4 4

106778-002 End Reflector for 4069-18-XX 4 4 4 4

106779-001 Top Cover for 4069-12-10 1

106779-002 Top Cover for 4069-12-16 1

106779-003 Top Cover for 4069-12-25 1

73

74

75

76**

77 106790-001-A Fan-260cfm,24vdc 1 1 1 1 1 1 1 1
79 083314-002 Connector-Flex Conduit Straight 1.00in 2 2 2 2 2 2 2 2
80 083310-002 Conduit- 1" (12 ft ea) 24 ft 24 ft 24 ft 24 ft 24 ft 24 ft 24 ft 24 ft
81 083313-002 Connector-Flex Conduit 90deg 1.00in 2 2 2 2 2 2 2 2

106779-003 Top Cover for 4069-12-38 1

106718-001 Top Cover for 4069-18-10 1

106718-002 Top Cover for 4069-18-16 1

106718-003 Top Cover for 4069-18-25 1

106718-004 Top Cover for 4069-18-38 1

106780-001 Bottom Cover for 4069-12-10 1

106780-002 Bottom Cover for 4069-12-16 1

106780-003 Bottom Cover for 4069-12-25 1

106780-004 Bottom Cover for 4069-12-38 1

106719-001 Bottom Cover for 4069-18-10 1

106719-002 Bottom Cover for 4069-18-16 1

106719-003 Bottom Cover for 4069-18-25 1

106719-004 Bottom Cover for 4069-18-38 1

106781-001 Fan Housing, 4069-12-XX 1 1 1 1

106781-002 Fan Housing, 4069-18-XX 1 1 1 1

106783-011

107358-011

106783-012

107358-012

106783-013

107358-013

106783-014

106783-014

106784-011

107396-011

106784-012

107396-012

106784-013

107396-013

106784-014

107396-014

Gas Spring for 4069-12-10
Gas Spring for 4069-12-10 w/safety Latch
Gas Spring for 4069-12-16
Gas Spring for 4069-12-16 w/safety Latch
Gas Spring for 4069-12-25
Gas Spring for 4069-12-25 w/safety Latch
Gas Spring for 4069-12-38
Gas Spring for 4069-12-38 w/safety Latch
Gas Spring for 4069-18-10
Gas Spring for 4069-18-10 w/safety Latch
Gas Spring for 4069-18-16
Gas Spring for 4069-18-16 w/safety Latch
Gas Spring for 4069-18-25
Gas Spring for 4069-18-25 w/safety Latch

Gas Spring for 4069-18-38
Gas Spring for 4069-18-38 w/safety Latch

1
1

1

1

1

1
1

1
1

1
1

1
1

1
1

1

* Only one set of lamps needed for each heater. Please consult factory if lamp type is not known.

** Item #76 is a replacement assembly consisting of Items 76,15, and 23 (Gas Strut, Ball End Socket, &
reflective shield).

***Item 58 is a replacement assembly consisting of Items 58 and 64 (Flow switch and fittings)

7-4

APPENDIX

This section contains associated schematics for the Model 4069 Heater