Precision Control Systems 5306B User Manual

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Model 5306B User’s Manual

Rev.112811

Instruction Manual

StripIR Model 5306B

7128 Shady Oak Road  Eden Prairie, MN 55344 (952) 949-9009 Fax (952) 949-9559

www.researchinc.com [email protected]

Another quality product from:

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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..................................................... 6-2

6.3 Cleaning the Reflector...................................................................................... 6-3

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

106837-001 Rev. 1

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Section 1 – INTRODUCTION

The Model 5306B StripIR® Infrared line heater is designed for use in any application that requires a clean, responsive, non-contact heat source.

Typical applications for the Model 5306B include:

Drying paint Curing adhesive Drying ink Forming plastic Stress relieving metal

Heat treating

The Model 5306B 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, 5, 11, 16, 25, and 38 inches (65, 127, 279, 406, 635, and 965 mm) are offered for the Model 5306B. Additional lamps can be ordered separately from the heater.

Water Cooling – Adequate cooling water is required during operation of the Model 5306B. Flexible tubing and plumbing fittings are supplied with each heater for easy installation. Required cooling water flow rates are listed in Specifications.

Electrical Cable – The Model 5306B 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 5306B. 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.

1. 106837-001 Rev. 1 1-1

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Figure 1-1. Model 5306 with the Control Option

Optional Power Control System – The Model 5306B can be ordered with the ‘PC’

option. This configuration consists of the heater, the Model 5420 ControlIR® controller, and eight feet (2.4 m) of electrical cable connecting the heater to the controller. Please see the Model 5420 ControlIR® product data sheet for further detail.

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Section 2 – FEATURES & BENEFITS

The design and functionality of the Model 5306B 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 enclosure and extruded aluminum construction of the Model 5306B, combined with the liquid, 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 5306B ordered with the Controller option is a complete heating solution designed with a number of features including heater on/off control switching, potentiometer local control, with or without a timer or a remote 4-20 ma control signal.

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Specification

5306B-02

5306B-05

5306B-10

5306B-16

5306B-25

5306B-38

Weight, Pounds (kg)

1.6 (0.60)

2.2 (0.82)

3.1 (1.2)

4.1 (1.5)

5.8 (2.2)

8.1 (3.0)

Lamp Type

QIH120-

1000RI2

QIH2401000R12

QIH2402000R12

QIH2403000R12

QIH6005000R12

QIH4803800R12

Lamp Part Number

106587-001

103390-002

103390-004

103390-012

103390-008

103390-010

Lighted Length, Inches (mm)

2.56 (65)

5.0 (127)

11.0 (279)

16.0 (406)

25.0 (635)

38.0 (965)

Watt Density (W/in)

266

133

125

Rated Voltage

120

240

600

480

Total Power Dissipated @ Rated Voltage, Watts

1000

2000

3000

5000

3800

Total Current @ Rated Voltage, Amps

8.3

4.2

8.2

12.5

8.3

7.9

Cooling Water Flow1, GPM (lpm)

0.15 (0.5)

0.25 (0.9)

0.4 (1.5)

0.6 (2.2)

0.45 (1.7)

Section 3 - SPECIFICATIONS

1. Cooling water must be used on all Model 5306B heaters while in operation.

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Model Number

Dimension

Inches (mm)

5306B-02-1000

6 (152.4)

2.5 (63.5)

5.3 (133.4)

5306B-05-1000

9.5 (241.3)

6 (152.4)

8.8 (222.3)

5306B-10-2000

14.5 (368.3)

11 (279.4)

13.8 (349.3)

5306B-16-3000

20.1 (510.5)

16.6 (421.5)

19.4 (491.5)

5306B-25-3550

29.5 (749.3)

26 (660.4)

28.8 (730.3)

5306B-38-3800

42.5 (1079.5)

39 (990.6)

41.8 (1060.5)

Figure 3-1. Model 5306 Dimensions

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Model

Product Description

5306B

Infrared Strip Heater (Installed lamp included)

Code

Length

Lighted Lamp Length

Reflector Length

Overall Heater Length

02-1000

2 in (51 mm)

2.56 in (65 mm)

5.3 in (133 mm)

6 in (152 mm)

05-1000

5 in (127 mm)

8.8 in (222 mm)

9.5 in (241 mm)

10-2000

10 in (254 mm)

11 in (279 mm)

13.8 in (349 mm)

14.5 in (368 mm)

16-3000

16 in (406 mm)

19.4 in (492 mm)

20.1 in (511 mm)

25-3550

25 in (635 mm)

28.8 in (730 mm)

29.5 in (749 mm)

38-3800

38 in (965 mm)

41.8 in (1061 mm)

42.5 in (1080 mm)

Code

Optional Equipment

No optional controls.

Controller including potentiometer

Controller including potentiometer and timer

Controller including an input for a remote 4-20 mA control signal

Model

Heating Chamber Length

Optional Equipment

Typical Model Number:

5306B

16-3000

Model

Description

Quartz Window Kit for:

W-5306B-02

2 Inch (51 mm) length

W-5306B-05

5 Inch (127 mm) length

W-5306B-10

10 Inch (254 mm) length

W-5306B-16

16 Inch (406 mm) length

W-5306B-25

25 Inch (635 mm) length

W-5306B-38

38 Inch (965 mm) length

Quartz Halogen, Ceramic End-Seal, Infrared Lamp for:

106587-001

Model 5194-02 (1000-watts, 120-volts)

103390-002

Model 5194-05 (1000-watts, 240-volts)

103390-004

Model 5194-10 (2000-watts, 240-volts)

103390-012

Model 5194-16 (3000-watts, 240-volts)

103390-008

Model 5194-25 (5000-watts, 600-volts/3550watts @480 volts)

103390-010

Model 5194-38 (3800-watts, 480-volts)

Other Available Lamps:

103390-001

Model 5194-05 (500-watts, 120-volts)

103390-003

Model 5194-10 (1000-watts, 240-volts)

103390-005

Model 5194-16 (1600-watts, 240-volts)

103390-007

Model 5194-25 (2500-watts, 480-volts)

103390-009

Model 5194-38 (3800-watts, 570-volts)

Accessories:

106684-001

Electrical Power Cable, 8-foot (2.4 m) length

106685-001

Water-Cooling Supply Kit

M5306B

Additional Operation Manual

Ordering Information – Model 5306B

Ordering Example – Model 5306B

Accessories, Spare & Replacement Parts – Model 5306B

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Section 4 – SAFETY GENERAL: The Model 5306B 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.

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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.

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Figure 5-1. Typical Model 5306B Installation.

Section 5 – INSTALLATION

5.1 UNPACK AND CHECK FOR DAMAGE: Remove the Model 5306B 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 5306B 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 5306B heater are designed for vertical operation, except for the lamps used in the 5306B-02.

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5.3 HEATER COOLING CONNECTIONS: Each Model 5306B is designed with two ‘quick-disconnect’ fittings protruding from the top of the heater cover. The fittings located at the outer ends of the heater are the inlet/outlet cooling water ports.

Both fittings accept 1/4-inch outer-diameter flexible nylon tubing. A 20-ft. (6 m) length of tubing and two additional quick-disconnect fittings are shipped with each Model 5306B heater. The tubing should be cut to specific lengths so that cooling water can be supplied to the heater. The additional fittings should be used for connecting the tubing directly to the cooling water 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 sources. Figure 5-2 details a typical installation for the Model 5306B heater.

Proper coolant flow must be maintained during operation of the heater. See Section 3 – Specifications for required cooling-water flow for each Model 5306B heater size.

5.4 ELECTRICAL CONNECTIONS: The T3 lamp of the Model 5306B 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 PC option, this cable is directly hard wired into the Model 5620 power controller.

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Figure 6-1. Model 5306B End Cover Removal.

Section 6 – MAINTENANCE

The repair and maintenance of the Model 5306B 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 5306B heater when shipped from the factory. The following procedure details the process to replace the lamps in the Model 5306B (reference Figure 6-1,& 6-2):

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 (1 per end cover).

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

106837-001 Rev. 1 6-1

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Figure 6-2. Model 5306 Lamp Removal.

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

of the heater and remove the lamp lead from the terminal block. (see Figure 6-2).

4. 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. (The model 5306B-02 does not have lamp clips, but a half-circle groove that the lamp fits in.)

5. If the heater has a window installed it may have to be removed before the lamp

can be removed. Remove the end cover enclosures screws with a 9/64 hex wrench. This will allow the window to be removed and access to the lamp. Install the new lamp and install the window back into the reflector. With the 2 hex screws remount the end enclosure back onto the reflector.

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].

106837-001 Rev. 1 6-1

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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 by replacing the screws in the window brackets.

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].

6.2 Quartz Window Cleaning and Replacement: The optional quartz window can be replaced or removed from the Model 5306B for periodic cleaning. Use the following procedure to remove/reinstall/clean the quartz window:

1. Loosen the screw that holds the lamp end cover to the end enclosure and remove

the end cover from the end without the electrical wires coming out of the end enclosure. Remove the lamp lead from the ceramic block. Unclip the lamp from its holder. With a 9/64 hex wrench remove the 2 screws that mounts the enclosure to the reflector.

2. Carefully slid the window out of the reflector.

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. Reinstall the quartz window into the reflector and reassemble the end enclosure,

hook the lamp back up and clip it back into place..

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. This energy is lost energy.

The following procedure should be used to clean the Model 5306B 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. Replace the lamps, quartz window (if so desired), and the heater end covers as outlined in Section 6.1 – Lamp Removal/Replacement/Installation.

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ITEM

PART NO.

DESCRIPTION

5306B-

054979-001

Panhead Screw, 2-56X3/16

N/A 2 2 2 2 2 2

054979-026

Panhead Screw, 4-40X3/4

1 2 2 2 2 2 3

054979-099

Panhead Screw, 8-32X5/8

6 6 6 6 6 6 4

054979-123

Panhead Screw, 10-32X.5

4 4 4 4 4 4 5

063042-001

Plug, 1/2NPT X 1/4LG

1 1 1 1 1 1 6

100571-001

Terminal Block, 10A

1 2 2 2 2

2 7 106587-001

Lamp-QIH120-1000W

1 103390-002

Lamp-QIH240-1000W

1 103390-004

Lamp-QIH240-2000W

1 103390-012

Lamp-QIH240-3000W

1 103390-008

Lamp-QIH600-5000W

1 103390-010

Lamp-QIH480-3800W

1 8

103830-001

Fittting-1/8NPT x 1/4"

2 2 2 2 2 2 9

103831-001

Spring Clip

N/A 2 2 2 2 2 10

106684-001

Power Cable Assembly, 8ft

1 1 1 1 1 1 11

106833-002

End Casting

2 2 2 2 2

106834-001

Reflector-5306B-02

1 106834-002

Reflector-5306B-05

1 106834-003

Reflector-5306B-10

1 106834-004

Reflector-5306B-16

1 106834-005

Reflector-5306B-25

1 106834-006

Reflector-5306B-38

106835-001

End Cover

2 2 2 2 2

W-5306B-02