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I
Instruction Manual
106223-001 – Rev B
Cool
Model C100 - Cooling System
May 2007
R
Research, Inc. • USA • Ph: 952.949-9009 • Fax: 952.949-9559 • [email protected]
• www.researchinc.com
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Table of Contents
List of Figures.......................................................................................................................... 2
Section 1 - Introduction ........................................................................................................... 3
Section 2 - Installation and Operation: .................................................................................... 4
Safety .................................................................................................................................. 4
Installation ........................................................................................................................... 5
Operation ............................................................................................................................. 6
Section 3 - Specifications ........................................................................................................ 7
Section 4 - Maintenance and Parts ......................................................................................... 8
Maintenance ........................................................................................................................ 8
Parts .................................................................................................................................... 8
List of Figures
Figure 1 - C100 with 5305 Heater ........................................................................................... 3
Revision History
Revision Description ECN Number By Date
A Initial Release 19336 NRC 06/06/01
B Mixture ratio
Phone / fax
KJN 05/09/08
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Research, Inc. • USA • Ph: 952.9419-9009 • Fax: 952.949-9559 • [email protected] • www.researchinc.com
Page 3
Section 1 - Introduction
The Model C100 cooling system is designed to provide water-cooling for small Research
Inc. aluminum-reflector heaters. The photograph to the left shows the C100 providing
cooling for a Model 5305 heater. (Note: Heater and lamp are sold separately.) The unit
includes a self-contained pump, coil, blower unit, and 6 gallon (23 liter) reservoir. A kit with
quick disconnect fittings is available to provide cooling requirements for the following
heaters:
StripIR
LineIR® 5193 / 5194 (all sizes)
ChambIR
®
5305 / 5306 (all sizes)
®
E4 (up to 10 inch lamp – may require 2 – C100 units)
Figure 1 - C100-120 with 5305 Heater
A water/glycol mixture is circulated through the closed system. As the liquid is heated as it
passes through the heater. The liquid is cooled by the self-contained blower/coil unit in the
C100. The C100 kit comes with quick disconnect fittings and plastic tubing for quick
installation and maintenance.
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Section 2 - Installation and Operation:
Safety
The maximum water/glycol temperature is 140ºF (60ºC). Precaution should be taken to
ensure this temperature is not exceeded. Refer to the installation section for proper sizing
instructions.
WARNING!
Hazardous voltages are present within the heating/cooling/control system. Setting the set
point potentiometer or control signal to minimum does NOT eliminate these hazardous
voltages.
Always remove AC line voltage from the system before making contact with internal
assemblies, line or load wiring, or fuses.
CAUTION!
Up to 480 volts AC may be present with longer heater length (25” and 38”).
Do not make any wiring connections when power is applied.
Disconnect power before performing any maintenance or service to the system.
Use extreme caution when adjusting calibration potentiometers on modules when
power is applied.
Always use an isolated oscilloscope for checking waveforms.
Sizing
The C100 can handle up to 3.3 KW of cooling load. The amount of cooling load is
dependent upon the heater style, lamp wattage, and heating application. Table 1 shows
how to size the C100. These steps are outlined below:
1. Determine heater wattage – This is a simple calculation based upon the wattage of
the lamps in the heater times the number of lamps in the system.
2. Determine the cooling factor (Fc). This takes into account how much heat is going
into the reflector that will be carried away by the cooling system.
3. Determine the number of C100 units required. Each C100 can handle up to 3.3 KW.
If the calculated cooling load is less than 3.3 KW, then one unit will work. Multiple
C100 units can be used in parallel. Consult factory.
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Size C100 CoolIR
1. Determine heater(s) wattage
Example: E4-05 w/500 watt lamps
Wattage = 4 x 500 = 2000 watts
2. Determine cooling factor (Fc)
Model Fc Description
E4 0.9 All
5193 0.9 Multiple 5193's facing each other
5193 0.7 5193(s) facing target > 800 ºC
5193 0.5 5193(s) facing target from 400 ºC to 800 ºC
5193 0.3 5193(s) facing target < 400 ºC
5305 0.9 Multiple 5305's facing each other
5305 0.6 5305(s) facing target > 800 ºC
5305 0.4 5305(s) facing target from 400 ºC to 800 ºC
5305 0.2 5305(s) facing target < 400 ºC
3. Calculate cooling load (Lc)
Lc = Heater wattage x Fc
Example: Lc = 2000 x 0.9 = 1800 watts
4. Determine number of C100's needed
C100 rating = 3300 watts
Lc = 1800 watts
1 - Model C100-1 required
Table 1 - C100 Heater/Cooler Sizing
Installation
1. Connect the water fittings to the cooling unit and the heater. Use Teflon tape thread
lubricant around the pipe thread fittings. Refer to the figures in the back of this
manual for installation with various heater configurations.
2. Connect water hoses to fittings marked "Water From Welding Equipment" and Water
To Welding Equipment". The “Welding Equipment” is the IR heater. Flow direction
through the heater does not matter.
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3. Remove filler cap and fill reservoir with mixture of 4 gallons distilled water and 1
gallon propylene glycol (RV type, pink color) solution. Do not use anti-freeze with
stop leak additive, which will clog the filter screen and damage the pump. Replace
the filler plug.
CoolIR Performance
160
140
120
100
80
60
Water Temp (F)
40
20
0
0.0 1.0 2.0 3.0 4.0
Cooling KW
Table 2 - C100 Cooling Performance
Caution:
Water should be allowed to flow through the system continuously. Pump will run hot,
shortening its life, if allowed to operate for more than a short period against a closed or
plugged discharge. When used with automatic equipment having a water solenoid
valve, bypass the solenoid or, wire the cooler into the equipment so that it operates
only during operation.
Do not transport or attempt repair unless unit is disconnected from power source.
Operation of the pump without coolant will cause serious damage.
Pump warranty is void if user opens or disassembles the pump.
Pump life and fitting life will be reduced if water temperature in tank exceeds 140°F
(60°C). Table 2 shows the water temperature as a function of cooling KW.
Operate the cooler only at the voltage and frequency stamped on the serial nameplate
(120V, 50/60 Hz), (230V, 50/60 Hz)
Operation
The C100 system needs to run when the heater is being run. After the heater is shut off, the
user should continue to run the C100 system for 3 – 5 minutes to allowing the heater to cool.
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Section 3 - Specifications
Dimensions:
21 1/4" long x 13 1/8" wide x 20 3/4" high
(54.0cm x 33.3cm x 52.7 cm)
Reservoir:
6-gallons capacity - stainless steel
Pump Capacity:
100 psi max.
1.5 gpm (5.68 lpm) @ 50 psi.
Heat Exchanger:
High efficiency, copper core, rustproof
Motor Voltage:
115 Volt AC, single phase, 50/60 Hz
230 volt AC, single phase, 50/60 Hz
Amperage:
115 volts: 5.0 amps
230 volt: 3.0 amps
Water Connections:
1/4" N.P.T. supplied with 5/8"-18 UNC left hand thread fitting
Net Weight:
56 lbs. (25.4 kg)
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Section 4 - Maintenance and Parts
Routine Maintenance
Perform the following maintenance on a minimum of 3 month time cycle:
Remove dust from radiator by means of compressed air, in order to insure optimum
cooler performance.
Check the filter screen for sediment, by removing the 15/16" acorn nut on the pump.
Clean the filter or replace as necessary.
Empty and flush water reservoir yearly. Remove filler cap and fill reservoir with
mixture of distilled water (4 gallons) and propylene glycol (1 gallon, RV type, pink
color) solution. Do not use anti-freeze with stop leak additive, which will clog the filter
screen and damage the pump.
Parts
Part Number Product Description
086813-004 C100 Base Unit (cooling unit only)
106217-001 Fitting and Hose Kit (connect 1st heater)
106218-001 Tee Kit (connect additional heaters)
099076-001 Spare water pump
120034-001 Anti-freeze, water conditioner
Table 3 - C100 Parts and Kits
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Research, Inc. • USA • Ph: 952.9419-9009 • Fax: 952.949-9559 • [email protected] • www.researchinc.com
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