Precision Control Systems 5194 User Manual

Model 5194 User’s Manual

Publication #: A106687-001 Rev. 1

January 2003

Another quality product from:

7128 Shady Oak Road, Eden Prairie, MN 55344

Phone: [phone] Fax: [phone]

E-mail: [email protected]

www.researchinc.com

Copyright © 2009 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 5194 LineIR

®

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 5194 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 5194.

Requirement

Appropriate Contact

Additional information regarding application Your local sales representative.
of the Model 5194 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............................................................... 3-3

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

5.4 Electrical Connections...................................................................................... 5-2

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

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

6.2 Quartz Window Cleaning and Replacement..................................................... 6-4

6.3 Cleaning the Reflector...................................................................................... 6-4

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

106687-001 Rev. 2

Section 1 – INTRODUCTION

The Model 5194 LineIR® Infrared line heater is designed for use in any application that
requires a clean, responsive, non-contact heat source.

Typical applications for the Model 5194 include:

Soldering
Unsoldering
Drying ink
Forming plastic
Curing epoxy
Heat treating

The Model 5194 includes the following major components:

Heater Module – The heater consists of a specular aluminum reflector that directs the
infrared energy generated by one ceramic end-seal ‘T-3 style’ quartz halogen lamp
factory-installed in the heater. Heated lengths of 2.56, 2.95, 5, 11, 16, 25, and 38 inches
(65, 75, 127, 279, 406, 635, and 965 mm) are offered for the Model 5194. Additional
lamps can be ordered separately from the heater.

Water Cooling – Adequate cooling water is required during operation of the Model

5194. Flexible tubing and plumbing fittings are supplied with each heater for easy
installation. Required cooling water flow rates are listed in Specifications.

106687-001 Rev.2 1-1

Air Cooling – Clean, dry compressed air cooling must also be supplied to the heater for
proper operation if using a quartz window and at all times with the 5194-02 and 5194-04.
This cooling air removes excess heat from around the lamp end-seals. Flexible tubing and
matching plumbing hardware is included with each heater. Required airflow rates and
pressures are listed in the specifications.

Electrical Cable – The Model 5194 heater is electrically wired from the T3 lamp to
intermediate terminal block within the heater. An 8-foot (2.4 m) electrical cable is
supplied with each heater.

Optional Quartz Window – A quartz window can be ordered along with each size of the
Model 5194. 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 Ceragold End Reflectors – Ceragold end reflectors are available for
installation on the ends of the heater module. These reflectors prevent infrared energy
from radiating past the ends of the heater.

Optional Power Control System – The Model 5194 can be ordered with the ‘PC’
option. This configuration consists of the heater, the Model 5420 ControlIR® 5420­power controller, and eight feet (2.4 m) of electrical cable connecting the heater to the
controller. Please see the Model 5620 ControlIR® product data sheet for further detail.

Figure 1-1. Model 5194 with the control Option

106687-001 Rev.2 1-2

Section 2 – FEATURES & BENEFITS

The design and functionality of the Model 5194 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 cast end enclosures and extruded aluminum construction
of the Model 5194, 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 5194 ordered with the control option is a complete heating solution designed
with a number of features including heater on/off control switching, a potentiometer for
local control, with or without a timer, or a remote 4-20 ma control signal.

106687-001 Rev. 2 2-1

Section 3 - SPECIFICATIONS

Specification 5194-02 5194-04 5194-05 5194-10 5194-16 5194-25 5194-38

Weight, Pounds (kg) 2.7 (1.2) 3.3 (1.4) 4.2 (1.9) 6.3 (2.8) 8.7 (3.9) 12.7 (5.7) 18.3 (8.3)
Lamp Type
Lamp Part Number 106587-001 106587-002 103390-002 103390-004 103390-012 103390-008 103390-010

Lighted Length, Inches
(mm)

Watt Density (W/in) 390 678 200 182 187.5 142 100
Rated Voltage 120 120 240 240 240 480 480

Total Power Dissipated
@ Rated Voltage,
Watts
Total Current @ Rated
Voltage, Amps
Cooling Water Flow1,
GPM (lpm)
Cooling Air Flow,
SCFH
(M3/hr.)

1. Cooling water must be used on all Model 5194 heaters while in operation.

2. Cooling air must always be supplied to the Model 5194-02 & 5194-04 while the heater is operational.

3. Cooling air is required on this model if optional quartz window is installed. Cooling airflow is not required if
window is not installed on the heater.

QIH120­1000RI2

2.56 (65) 2.95 (75) 5.0 (127) 11.0 (279) 16.0 (406) 25.0 (635) 38.0 (965)

1000 2000 1000 2000 3000 3550 3800

8.3 16.7 4.2 8.3 12.5 7.4 7.9

0.15 (0.5) 0.25 (0.9) 0.15 (0.5) 0.25 (0.9) 0.4 (1.5) 0.6 (2.2) 0.45 (1.7)

30 (0.85)

QIH120­2000RI2

2

30 (0.85)2 30 (0.85)3 40 (1.1)3 50 (1.4)3 60 (1.7)3 50 (1.4)3

QIH240­1000R12

QIH240­2000R12

QIH240­3000R12

QIH600­5000R12

QIH480­3800R12

106687-001 Rev. 2 3-1

Dimension

Model Number

5194-02-1000 6.1 (154.9) 3.35 (85) 2.6 (66.0) 2.7 (1.2)

5194-04-2000 7.5 (190.5) 4.75 (120.6) 4 (101.6) 3.3 (1.4)

5194-05-1000 9.5 (241) 6.75 (171.4) 6 (152.4) 4.2 (1.9)

5194-10-2000 14.5 (368) 11.75 (298) 1 1 (279) 6.3 (2.8)

5194-16-3000 20.1 (510) 17.35 (440) 16.6 (421) 8.7 (3.9)

5194-25-3550 29.5 (749) 26.75 (679) 2 6 (660) 12.7 (5.7)

5194-38-3800 42.5 (1079) 39.75 (1009) 39 (990) 18.3 (8.3)

A

Inches (mm) B Inches (mm) C Inches (mm)

Heater

Weight,

Pounds (kg)

Figure 3-1. Model 5194 Dimensions

106687-001 Rev.2 3-2

Ordering Information – Model 5194

Model Product Description

5194 Infrared Line Heater (Installed lamp included)

Code Length

02-1000 2 Inches (51 mm) 2.56 Inches (65 mm) 2.6 Inches (66 mm) 6.1 Inches (155 mm)
04-2000 4 Inches (102 mm) 2.95 Inches (75 mm) 4 Inches (102 mm) 7.5 Inches (191 mm)
05-1000 5 Inches (127 mm) 5 Inches (127 mm) 6 Inches (152 mm) 9.5 Inches (241 mm)
10-2000 10 Inches (254 mm) 11 Inches (279 mm) 11 Inches (279 mm) 14.5 In ches (368 mm)
16-3000 16 Inches (406 mm) 16 Inches (406 mm) 16.6 Inches (421 mm) 20.1 Inches (510 mm)
25-3550 25 Inches (635 mm) 25 Inches (635 mm) 26 Inches (660 mm) 29.5 In ches (749 mm)
38-3800 38 Inches (965 mm) 38 Inches (965 mm) 39 Inches (990 mm) 42.5 Inches (1079 mm)

Code Optional Control Equipment

00 No optional controls.
02 Controller including potentiometer
03 Controller including potentiometer and timer
04 Controller including an input for a remote 4-20 mA control signal

Lighted Lamp
Length

Reflector Length Overall Heater Length

Ordering Example – Model 5194

Typical Model Number:

Model Heating Chamber Length Optional Equipment

5194 16-3000 03-00

Accessories, Spare & Replacement Parts – Model 5194

Model Description

106586-001 Quartz Window Kit, Model 5194-02
106586-002 Quartz Window Kit, Model 5194-04
106586-003 Quartz Window Kit, Model 5194-05
106586-004 Quartz Window Kit, Model 5194-10
106586-005 Quartz Window Kit, Model 5194-16
106586-006 Quartz Window Kit, Model 5194-25
106586-007 Quartz Window Kit, Model 5194-38

106587-001 Quartz-Halogen Infrared Lamp, Ceramic End Seal, Model 5194-02
106587-002 Quartz-Halogen Infrared Lamp, Ceramic End Seal, Model 5194-04
103390-002 Quartz-Halogen Infrared Lamp, Ceramic End Seal, Model 5194-05
103390-004 Quartz-Halogen Infrared Lamp, Ceramic End Seal, Model 5194-10
103390-012 Quartz-Halogen Infrared Lamp, Ceramic End Seal, Model 5194-16
103390-008 Quartz-Halogen Infrared Lamp, Ceramic End Seal, Model 5194-25
103390-010 Quartz-Halogen Infrared Lamp, Ceramic End Seal, Model 5194-38

106684-001 Electrical Power Cable, 8-foot (2.4 m) length
034766-001 Ceragold End Reflectors (set of 2)

106686-001

C100-1

KFS-5420 Foot switch for remote start

Air-Cooling Supply Kit (Includes flexible tubing and plumbing fixtures for connection to
compressed air supply)
Water-Cooling Supply Kit (Includes flexible tubing and plumbing fixtures for connection to

cooling water supply)

106687-001 Rev. 2 3-3

Section 4 – SAFETY
GENERAL: The Model 5194 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.

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.

106687-001 Rev. 2 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.

106687-001 Rev. 2 4-2

Section 5 – INSTALLATION

5.1 UNPACK AND CHECK FOR DAMAGE: Remove the Model 5194 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 5194 heater should be mounted to a
framework or structure that is designed to support the weight of the heater and provide
stability to the unit. Four #10-32 threaded holes are located on the top surface of the
heater and are designed for mounting the heater (see Figure 3-2).

Note: All Research Inc. lamps associated with the Model 5194 heater are designed for
vertical operation, except for the lamps used in the 5194-02 and 5194-04.

Figure 5-1. Typical Model 5194 Installation.

106687-001 Rev. 2 5-1

5.3 HEATER COOLING CONNECTIONS: Each Model 5194 is designed with
three ‘quick-disconnect’ fittings protruding from the top of the heater cover. The two
fittings located at the outer ends of the heater are the inlet/outlet cooling water ports. The
single fitting located at the center of the heater is the cooling air inlet port.

All three fittings accept 1/4-inch outer-diameter flexible nylon tubing. A 30-ft. (9.1 m)
length of tubing and three additional quick-disconnect fittings are shipped with each
Model 5194 heater. The tubing should be cut to specific lengths so that both cooling
water and compressed air can be supplied to the heater. The additional fittings should be
used for connecting the tubing directly to the cooling water and compressed air source.

Once cut to the appropriate lengths, each individual tube length should be inserted into
the appropriate fittings on both the heater and the cooling water and compressed air
sources. Figure 5-2 details a typical installation for the Model 5194 heater.

Proper coolant flow must be maintained during operation of the heater. See Section 3 –
Specifications for required cooling water and compressed air flow for each Model 5194
heater size.

5.4 ELECTRICAL CONNECTIONS: The T3 lamp of the Model 5194 is
electrically wired to an intermediate terminal block within the heater.

Each heater is supplied with an 8-foot (2.4 m) electrical cable. If ordered with the
controller option, this cable is directly hard wired into the Model 5420 power controller.

106687-001 Rev. 2 5-2

Section 6 – MAINTENANCE

The repair and maintenance of the Model 5194 includes replacement of the T3-style lamp
and quartz window and cleaning of the reflector.

6.1 LAMP REMOVAL/REPLACEMENT/INSTALLATION: The T3-style lamp
is installed into the Model 5194 heater when shipped from the factory. The following
procedure details the process to replace the lamps in the Model 5194 (reference Figure 6­1, 6-2, & 6-3):

Note:

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

lamp.

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

is not taut when inserted into the lamp terminal block.

• 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 envelope.

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

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

Figure 6-1. Model 5194 End Cover Removal.

106687-001 Rev. 2 6-1

3. If installed in the heater, remove the quartz window from the heater by sliding the

window out of the slots machined into the reflector body (see Figure 6-2). Take
this opportunity to clean the window using isopropyl alcohol and a clean, soft
cotton cloth (see Section 6-2).

Quartz Window

Figure 6-2. Model 5194 Quartz Window Removal.

4. Loosen (do not remove) the setscrews in the ceramic terminal block on each end

of the heater (see Figure 6-3).

106687-001 Rev. 2 6-2

Figure 6-3. Model 5194 Lamp Removal.

5. While holding the lamp, gently pull the lead wires out of the ceramic terminal

blocks, out of the lamp clips, and set the old lamp aside for disposal. (Models
5194-02 and 5194-04 do not have lamp clips, but a half-circle groove that the
lamp fits in.)

6. While holding the replacement lamp by the ceramic end seals, place the lamp into

the lamp clips located on each end of the heater. Orient the lamp so that the gas
fill tip, formed into the quartz tube of the lamp, points out away from the
reflector.

7. 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.

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

Note: tighten the terminal block set screws to a torque of 0.6 Ft.-Lbs. [0.82 N-m].

9. Form a loop within each lead along its length from the top of the cooling manifold

and the ceramic terminal block. This loop will act as a strain relief within the lead
during normal operation of the heater.

10. Reinstall the quartz window within the heater by carefully sliding the window into

the grooves machined into the heater reflector.

11. Reinstall both end covers and secure each to the heater with the two screws per

end cover.

Note: tighten the end cover screws to a torque of 1.7 Ft.-Lbs. [2.3 N-m].

106687-001 Rev. 2 6-3

6.2 Quartz Window Cleaning and Replacement: The optional quartz window can
be replaced or removed from the Model 5194 for periodic cleaning. Use the following
procedure to remove/reinstall/clean the quartz window:

1. Remove the two end-cover screws and the end cover from one end of the heater.

2. Gently slide the quartz window out of the grooves within the heater reflector.

Take care so that the quartz window does not bind and subsequently chip or crack
as it is removed.

3. If cleaning the window, use isopropyl alcohol and a clean, dry, lint-free cloth.

After cleaning, do not touch the inside surface of the window unless wearing
cotton gloves.

4. Reinsert the edges of the window into the grooves machined into both sides of the

reflector body.

5. Gently push the window into the reflector until it is completely seated against the

end cover mounted to the heater.

6. Reinstall the other end cover and secure with the two end cover screws.

6.3 Cleaning the Reflector: A clean reflector provides the greatest radiant efficiency.
If the reflector surface becomes contaminated, it reflects less energy. The energy that is
not reflected is absorbed by the reflector, and removed by the cooling water and air. This
energy is lost energy.

The following procedure should be used to clean the Model 5194 reflector:

1. Remove the lamp as described in Section 6.1 – Lamp

Removal/Replacement/Installation.

2. Clean the reflector 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, quartz window (if so desired), and the heater end covers as

outlined in Section 6.1 – Lamp Removal/Replacement/Installation.

106687-001 Rev. 2 6-4

6

Section 7 – SPARE & REPLACEMENT PARTS

Fig. 7-1

Fig. 7-2

Fig. 7-3

1

Figures 7-1, 7-2, 7-3. Model 5194 Parts Identification.

106687-001 Rev. 2 7-1

Replacement parts for the Model 5194 are listed below. Reference Figures 7-1, 7-2, and
7-3 when using this list.

ITEM PART NO. DESCRIPTION 5194-02 5194-04 5194-05 5194-10 5194-16 5194-25 5194-38

1 054979-001 Panhead Screw, 2-56X3/16 N/A N/A 2 2 2 2 2
2 054979-026 Panhead Screw, 4-40X3/4 2 2 2 2 2 2 2
3 054979-097 Panhead Screw, 8-32X3/8 2 2 2 2 2 2 2
4 054979-099 Panhead Screw, 8-32X5/8 8 8 8 8 8 8 8
5 054979-123 Panhead Screw, 10-32X.5 4 4 4 4 4 4 4
6 063042-001 Plug, 1/2NPT X 1/4LG 1 1 1 1 1 1 1
7 100571-004 Terminal Block, 20A 2 2 2 2 2 2 2

106587-001 Lamp-QIH120-1000W 1
106587-002 Lamp-QIH120-2000W 1
103390-002 Lamp-QIH240-1000W 1

8

103390-004 Lamp-QIH240-2000W 1
103390-012 Lamp-QIH240-3000W 1
103390-008 Lamp-QIH600-5000W 1
103390-010 Lamp-QIH480-3800W 1

9 103830-001 Fittting-1/8NPT x 1/4" 3 3 3 3 3 3 3
10 103831-001 Spring Clip N/A N/A 2 2 2 2 2
11 106584-002 End Casting 2 2 2 2 2 2 2
12 106585-001 End Cover 2 2 2 2 2 2 2

13

14

15 034766-001 Option-End Reflector Kit, 5194-XX 1 1 1 1 1 1 1
16 106684-001 Power Cable Assembly, 8ft 1 1 1 1 1 1 1

106606-001 Reflector-5194-02 1
106606-002 Reflector-5194-04 1
106606-003 Reflector-5194-05 1
106606-004 Reflector-5194-10 1
106606-005 Reflector-5194-16 1
106606-006 Reflector-5194-25 1
106606-007 Reflector-5194-38 1

W-5194-02 Option-Quartz Window Kit, 5194-02 1
W-5194-04 Option-Quartz Window Kit, 5194-04 1
W-5194-05 Option-Quartz Window Kit, 5194-05 1
W-5194-10 Option-Quartz Window Kit, 5194-10 1
W-5194-16 Option-Quartz Window Kit, 5194-16 1
W-5194-25 Option-Quartz Window Kit, 5194-25 1
W-5194-38 Option-Quartz Window Kit, 5194-38 1

106687-001 Rev. 2 7-2