Research Inc. PanelIR 4554 Infrared Heater Instruction Manual

 Publication No. 098424-001 Rev. A
a]
=
Series
September 1998
Another quality product from:
Uca:
6425 Flying Cloud Drive
Eden Prairie, MN 55344 USA
(612) 941-3300 Fax (612) 941-3628
www.researchinc.com
Copyright © 1998 by Research, Inc. All rights reserved. Under copyright laws, neither the docu-
mentation 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.
Contents
Section 1
INTRODUCTION
Continuous Operation ........._.eee_.eseredarerererereererereerecer er rerereee ee 1-1
Rapid RESPONSE «oti titties 1-1
Modular Design .....1022 400444444444 ee a ea se RAA ee A4 A4 eee eee ee ee a ae a ee 1-1
Controllable Energy Output ......._...eo eee 1-1
Self-Cleaning Heater Modules ........ oii icine 1-1
Heater Description. ..................0esesrererirererer ear rev KK KK ea eee 6 1-1
Heater Module ..............00000re0cr0recrecrríe rr ereca re eerererererrrerrere 1-1
Forced Air Blowers ee ee ee ee 1-2
Bdge Reflectors o.oo. eee AA ea AAA eee Aa Re a ee eee ne ee ee ae 1-2
Lamps A AA K RK KK 1-2
Heater PerfOIMANCE . «vot ttt ttt te eee eee ee eee eee ee 1-3
Product TemperatureS o.oo tte eee eee 1-3
Product Sizes + ov vit tte es 1-3
Heat FIuX Densities «ee tee ee eee ie ee 1-3
Section 2
SAFETY
CE EEE ee 2-1
Infrared Radiation .. 110200000040 144 4 444 44 4e 4 4 A a 8 4 ee eee a eee ae a ee a ae 00 2-1
Heater Temperatures .. 000000404444 a a ee ee a Ra 4 ee ee ee aa a se ee sa a ra eee 2-1
Electrical Safety. ..........e.e00000000 ire dre 0er ei KK KK 2-1
Section 3
INSTALLATION
Mechanical Installation. ............ee.eecceorcore reso re deere ar riera er er eere—. 3-1
Electrical Installation. .........._eeeecomerecorerec o ereco recorre re ererorecerarererere. 3-2
Single-zone Wiring ............e0000a0rerierer e rececrerer ero errrere rece 06 3-2
Prepare heater unit for Wiring ...........eeeeeeerrerarererrrer res erre 0» 3-3
Remove electrical connection knock-outs? ............ee.reesdearr0rrer eee 3-3
Install high temperature Wire ..........eeerererroriirererere 0 erre 3-3
Wiring Power to Heater ...........o_.eeecreevedireierererecen ere er ea 3-4
Multi-zone wiring ..........eeoreeceoroeroorerer ía reccereareraerre recvore recreo, 3-4
Prepare heater unit for wiring . ..... oi aa ea ee ee a ea ee se ea 3-4
Remove electrical connection knock-outs” ........ ci i i вне ннвоее 3-4
Prepare bus bar to accommodate multiple zones ................ iano 3-4
Install high temperature Wire ......... cotinine 3-5
Wiring Power to Heater .......000000 04044 sea aa ea ea Rae 4 A4 A4 ee eee se ae 3-5
Lamp Installation. ........._.eé_eeeesderrriereerereerrerer rr A erererrereererarer. 3-5
Lamp wire preparation .....0000000040 er. 3-6
Mounting lamps © vette ete ee 3-6
Reinstall 60d COVES «ott tte cee a cea 3-7
Wiring Thermostat. . . o.oo. ie i i KK a 0e 3-8
Wiring Forced-Air BIOWer ...... oo ere 3-8
Remote-Mount Blower Kit ©... i ie ee eee ee ee 3-9
——— Section4
MAINTENANCE
Section 5
OPERATING INSTRUCTIONS
Section 6
DIMENSIONS AND
SPECIFICATIONS
Specifications ..............
а зонт ха и чан нео ви живи веки ви Фи во и хи ео жж дя таке во як чья
Ordering Information — Model 4554 ..............0mev0ervereierrecerea reee
Ordering Example-Model 4554
+ + % + % + 4 + + 4 4 1 5 + + + + +4 в чи тв к еж я вв о # FF oF 5 4 FF FF x 3 a Ad + + + 0
Accessories, Spare & Replacement Parts-Model 4554 ........... ooo sa aa eee
Lamps —4554 ..............
Dimensions — Model 4554 ....
Appendix A
Determining the Current per Lamp .
Single-Phase Loads .........
Three-Phase Balanced Loads . .
Three-Phase Unbalanced Loads
= + 5 + à # аня в я и + # + 5 2 + 4 à EH + BF ао тя тн жа в FX KF + а KERN AK N
1 + + # KE #4 4 #4 4 5 A Wm + + & BF 4 +4 к яв ев кассе я ки ке тже сн + не ан в ки к нана
= 4 AAA A вт хи живее тв хина в = BE oF HE 4 FF ке тени ка не Ж +
в а вынес OE +4 % = + + 4 4 + + + # #4 4 EF AR OF mE EEE AECE EEE +
A ow mB à #4 BE OW OM + + ков вто вв 2 + + 4 # 3 вов важ но a = = = #4 5° 4 F&F BE AAA
» à + + + 4 à 1 +5 + + F #4 8 = + 5 + 4 ® 5 EA ESA EEE EEN
6-1
6-2
6-3
6-3
6-4
A-1
A-2
A-4
А-7
The-absorption/emission characteristics-of the ceramic. reflector-surfaces.in the heater
Forced Air Blowers
Edge Reflectors
Lamps
module maintain a high surface temperature that continually vaporizes organic
contaminants. The reflector material also serves as a re-emitter of medium wave (3 to 4
micron) infrared energy. This can be beneficial in many processes depending on the
absorptive properties of the material being heated.
An electrical bus bar terminal strip is located in each end of the Model 4554 for easy lamp
wiring connection. This configuration allows for either individual lamp wiring or for
specific ‘zones’ to be generated by wiring multiple lamps together.
A thermostat is mounted to the backside of the Model 4554 heater module that can be
wired directly to the power source or to an external failure indicator (i.e. an alarm, failure
light, etc.). The thermostat will either remove power from the unit or trip the external
indicator if the heater exceeds the thermostat trip temperature.
The back of the Model 4554 heater module contains four 1/4-20 inch Phillips head screws
installed for mounting the heater in nearly any application.
The Model 4554 is available in heated lengths of 5, 10, 16, 25, and 38 inches (127, 254,
406, 635, and 965 mm) and heated widths of 3, 6, or 12 inches (76, 152, and 305 mm).
Model 4554 heaters with 3 inch heated widths use 4 lamps installed on 0.75 inch (19 mm)
centers. All other models us either 6 or 12 lamps installed on linch (25 mm) centers.
Heated length and width are specified within the heater model number.
Heater- and remote-mounted forced air blowers are available for the Model 4554. These
assemblies include 120V and 230V versions (both operable at either S50 Hz or 60 Hz). Air
from the blowers is directed through holes in the heater reflector along the full length of
each lamp. This air cools the reflector and lamps while providing a preheated convection
air flow to improve the heating rate and power efficiency in most applications. Air flow
rates required to operate the various Model 4554 heaters are listed in Specifications.
Blowers for most Model 4554 heaters are specified within the model number or can be
ordered separately from the heater. The 3 inch (76 mm) wide heaters require
remote-mounted blowers that are ordered separately from the heater.
The edge reflectors are constructed from the same materials used in the heater modules.
Edge reflectors can also be specified within the heater model number or can be ordered
separately from the heater.
A variety of high intensity, short wave, tubular quartz, ‘T-3 style,” halogen lamps are
available for the different heated lengths of the Model 4554. The tungsten emitter in these
lamps has an operating temperature of approximately 4000 °F (2205 °C) with a spectral
energy peak wavelength of 1.15 microns. The numbers of lamps required to operate the
various Model 4554 heaters are listed in Specifications. The lamps are ordered and sold
separately from the Model 4554 heaters.
Model 4554 PanellR™ Instruction Manual introduction
EI A “Er
LAILMN
PERFORMANCE
Product Tem peratures Depending on the particular model, the Model 4554 heater can generate extremely high
energy levels. The maximum target work piece temperature depends upon the voltage
applied to the heater lamps, the ability of the work piece to absorb radiant energy, and the
amount of heat loss. For most continuous heating processes, the maximum work piece
temperature should not exceed 800°F (427°C).
Product Sizes Areas of up to 38 X 12 inches (965 x 305 mm) can be heated with a single heater. Larger
heated areas can be created by mounting two or more Model 4554 heaters side-by-side.
Heat Flux Densities There are two basic lamps types readily available for the Model 4554: 100 or 200 watts
per inch (3.9 or 7.9 watts per millimeter) of lighted length. Dissipated power for the
Model 4554 is either 100 or 200 watts per square inch (155 or 310 kilowatts per square
meter). The three inch wide Model 4554 heater has a 0.75 inch (19mm) lamp spacing and
dissipates 133 or 269 watts per square inch (206 or 414 kilowatts per square meter).
Model 4554 PanellR™ Instruction Manual
GENERAL
INFRARED
RADIATION
HEATER
TEMPERATURES
ELECTRICAL SAFETY
Safety
General The Model 4554 Heater is designed for safe operation in all installations.
However, the installation, maintenance, and operation of the heater can be dangerous if
proper installation and operating procedures are not followed. All of the instructions in
this manual should be followed to ensure proper heater installation and operation in order
to prevent accidental injury to operating personnel and/or surrounding equipment.
CAUTION!
Exposure to high intensity infrared radiation will cause severe burns to skin and
can be extremely harmful to eyes.
Appropriate protective eyewear must be worn when directly observing powered,
radiant energy lamps.
Certain areas of the Model 4554 heater my exceed 500°F (260°C) while the heater is in
operation. Exercise extreme care when working in close proximity to an operating heater.
Á WARNING!
NEVER place any part of the body under or near any part of the heater while
power is applied.
Always allow the heater to cool sufficiently (at least 5 minutes with blower
operating, longer if the blower is not operating) before servicing any part of the
heater, including lamps or adjacent parts.
Due to the high voltages present in typical Model 4554 installations there is danger of
electrical shock when installing, operating, or servicing the heater. Exercise extreme
caution when handling or working with these high voltages.
CAUTION!
All applicable local and national electrical codes should be followed to ensure
proper installation and operation of the Model 4554. A safe electrical ground must
also be provided and properly installed on the heater before attempting to operate
the unit
2-1
Model 4554 PanellR™ Instruction Manual
Research, Inc.
A WARNING!
Power lines and any other affiliated heater circuitry (i.e., blowers, thermostat, etc.)
must be disconnected prior to any servicing issue including lamp installation and
change-out.
The Model 4554 heater should never be operated with the end covers of the
heater removed.
The presence of open load-to-ground must be verified after lamp installation into
the Model 4554 and before system power is applied.
MECHANICAL
INSTALLATION
Figure 3-1
Typical installation
drawing for Model 4554
heater.
Installation
Tools Required:
Phillips Screwdriver
+ Slotted Screwdriver
Hammer
* Metal Punch
* Pliers
+ Tape Measure
* Tin snips/metal cutting scissors
As shown in Figure 3-1, four 1/4 X 20 screws are provided on the top of the Model 4554
heater for mounting purposes. The heater can be attached directly to a suitable frame
structure or mounting brackets using these four screws. The distance between the heater
and target should be determined before mounting the heater. The heater should be
mounted so that each end cover may easily be removed for lamp installation.
Multiple Model 4554 heaters can be mounted side-by-side to form large heating arrays.
Screws (4X)
1/4 x20 — >?
Mounting
Frame
Heater to
Target Distance
4
/
Target
CAUTION!
The back and end covers of Model 4554 heaters should not be exposed to
temperatures exceeding 425°F (218°C). The heater should not be surrounded or
enclosed by any type of insulating material.
3-1
research, Inc.
ELECTRICAL
DL GA
INSTALLATION
Figure 3-2 Terminal Strip and Bus
Bar
Single-zone Wiring
3-2
Model 4554 PanellR™ Instruction Manual
CAUTION!
All internal wiring of the Model 4554 PanellR should be high temperature
insulated wire as specified below or of an equivalent type:
* Lead wire type PFAH or TFE, 600V maximum, 250.*C maximum, UL listed.
* Ampacity based on National Electrical Code Table 310.
As shown in Figure 3-2, the Model 4554 contains two electrical terminal strips, one each
mounted on the internal heater housing, under each heater end cover. These terminal
strips each contain contact points for electrical connection of each lamp of the heater. In
addition, each terminal strip contains a ‘bus bar’ that provides electrical connection
between all contact points on the terminal strip (Figure 3-2).
Bus Bar
Electrical
'Knock-Outs'
ry,
es
tm
Heater
Housing
Terminal
/ / / Strip (2X
7 / Reflector / Pp (2X)
/
у /
y y
/
/
7 p
9 & /
y / |
$ & |
A
/
End Cover
The presence of the bus bars on each terminal strip allows the heater to be easily wired in
different configurations. A Model 4554 heater wired in a single-zone configuration is
shown in Figure 3-3. In this configuration, the lamps mounted in the Model 4554 all
simultaneously receive the same voltage from the power source. In this case, electrical
connection from each terminal strip to the power source is made by a single, high
temperature grade, electrical wire as follows:
Model 4554 PanellR™ Instruction Manual | installation
Prepare heater unit for wiring
Remove electrical
connection‘knock-outs’
Install high temperature wire
Heater Incoming
|
Terminal
47 Strip
Ceramic Reflector
The electrical power required to operate the Model 4554 is extremely dangerous.
Make sure all electrical power that is to be provided to the Model 4554 is
adequately turned off prior to making any electrical connection to the heater.
NOTE:
The following instructions are for single-phase electrical wiring of the Model 4554.
See Appendix A for three-phase wiring.
1.
Remove the three screws from each of the end covers on each end of the heater using
the Phillips screwdriver.
Carefully remove each of the end covers and set them aside so that the attached
reflector material is not damaged.
Using the hammer and punch, remove one circular ‘knock-out’ from each end of the
top of the heater by placing the metal punch on the knock-out outline and striking the
punch with the hammer until the knock-out slug protrudes into the heater.
Using the pliers, remove both knock-out slugs from the heater body.
Discard the knock-out slugs.
On each end, use the tape measure to measure the distance from the center of each
terminal strip to the point at which the supply power and the high temperature wire
are to be joined.
Include additional length to account for wire travel through the knock-out hole and
enough to perform adequate wire stripping prior to attachment to the heater and
power supply wiring.
Cut two lengths of high temperature wire corresponding to the measured lengths.
3-3
Research, Inc.
Wiring Power to Heater
Multi-zone wiring
Prepare heater unit for wiring
Remove electrical
connection knock-outs”
Prepare bus bar to
accommodate multiple zones
3-4
R™ Instruction Manual
4-8 trip-the-insulation from each end of each wire to expose the conductor material —
(approximately 1/2 inch).
5. Feed one wire (each) into the heater through each end of the heater between the
terminal strip and the back of the heater and up through the knock-out hole.
6. Attach one end of each stripped wire end to each terminal strip by partially backing
out one of the center-most screws holding the bus bar to the terminal strip and
wrapping the stripped portion of the wire around the screw. Retighten the screw on
each terminal strip back to its original position.
1. Attach the unconnected end of each high temperature wire to the power supply wiring
using appropriate wire joining techniques (as specified by local electrical codes and
standards).
The Model 4554 can also be wired so that multiple heating zones are produced within the
heater. When configured for multi-zone operation, each ‘zone’ of lamps is electrically
controlled by its own power control device. Wiring the Model 4554 for multi-zone
operation is as follows:
1. Remove the three screws from each of the end covers on each end of the heater using
the Phillips screwdriver.
2. Carefully remove each of the end covers and set them aside so that the attached
reflector material is not damaged.
1. Three knock-outs are provided on each end of the Model 4554. Multiple knock-outs
can be removed on each end of the heater so that an individual knock-out does not
have to accommodate more than three or four wires. It is left up to the installer to
determine the number of knock-outs to remove to simplify the wiring procedure.
2. Using the hammer and punch, remove one circular ‘knock-out’ from each end of the
top of the heater by placing the metal punch on the knock-out outline and striking the
punch with the hammer until the knock-out slug protrudes into the heater.
3. Using the pliers, remove the knock-out slugs from the heater body.
4. Discard the knock-out slugs.
1. Using the slotted screwdriver, loosen the screws holding the bus bar to the terminal
strip.
2. Lift the bus bar out of the terminal strip.
3. As shown in Figure 3-4, the bus bar can be cut to produce shorter, individual bus bars
corresponding to the number of desired heating zones. Using the tin snips/metal
cutting scissors, cut the bus bar apart into shorter, individual bus bars corresponding
to the number of lamps to be ‘bussed’ together to form each heating zone.
4, Place each individual bus bar back on the terminal strip corresponding to its ‘zone’
location.
5. Tighten each of the screws into the bus bar/terminal strip assembly.
Model 4554 PanellR™ Instruction Manual Installation
Figure-3-4— Multi-Zone-Bus-Bar
Preparation Bus Bar
A B A B
Y
7 7 7
\ / \ / vd
. Removal of this bus bar segment results in
" two separate '6-lamp' bus bars.
. Removal of these bus bar segment results in
" three separate '4-lamp' bus bars.
Install high temperature wire 1. On each end, use the tape measure to measure the distance from the center of each
terminal strip “zone” to the point at which the supply power and the high temperature
wire are to be joined.
2. Include additional length to account for wire travel through the knock-out hole and
enough to perform adequate wire stripping prior to attachment to the heater and
power supply wiring.
3. Cut lengths of high temperature wire corresponding to the measured lengths.
4. Strip the insulation from each end of each wire to expose the conductor material
(approximately 1/2 inch).
5. Feed the wires into the heater through each end of the heater between the terminal
strip and the back of the heater and up through the knock-out holes.
6. Attach one end of each stripped wire end to each terminal strip ‘zone’ by partially
backing out one of the center-most screws holding each bus bar to the terminal strip
‘zone’ and wrapping the stripped portion of the wire around the screw. Retighten each
screw on each terminal strip back to its original position.
Wiring Power to Heater Attach the unconnected end of each high temperature wire to the power supply wiring
using appropriate wire joining techniques (as specified by local electrical codes and
standards).
LAMP INSTALLATION
CAUTION!
Wear soft, clean, oil-free flannel or plastic gloves when handling halogen, quariz
lamps. Oils and contaminants are readily transmitted to the quartz by unprotected
hands and can cause premature lamp failure.
3-5
R™ Instruction Manual
Research, Inc. Model 4554 Panell
—— Lampwire preparation As-shown in Figure 3-5, new lamps are shipped with straight, “unbent’ wires M Eachlamp _ _
1 wire must be configured before installation into the heater as follows:
1. Make a small loop in the wire at a point far enough from the lamp end seal to allow
the lamp to be installed in the heater without putting tension in the wire. Wind the
remaining wire (beyond the loop) around the portion of the wire between the loop and
the lamp end seal.
Figure 3-5 Lamp Wire Preparation
NEW LAMP END SEAL
LOOP WITH
PIG TAIL 8
Mounting lamps 1. Place the ends of the lamps into the slots in the ceramic reflector material.
4684a
2. Using the slotted screwdriver, loosen the lower row of screws from the terminal strip.
3. Place one screw through each wire loop from each lamp and reinsert the screws into
the terminal strip locations they came from.
4. ‘Hand tighten’ each screw into the terminal strip using the slotted screwdriver.
5. Verify that there is no tension in each wire between the lamp and the terminal strip
(each wire should be able to move a small distance when so attempted by hand).
3-6
Model 4554 PanellR™ instruction Manual installation
Figure-3-6-—Mounting-Eamps
Heater Incoming
Power Terminal
|
Y
©! | | Terminal
TUE — Strip
Lamp 2 Ceramic
res Reflector
T3 Lamps
Reinstall end covers 1. Carefully replace each end cover in its proper location on the heater body.
2. Insert the three screws that hold the end cover in place into their respective holes and
tighten them into the heater using the Phillips screwdriver.
Figure 3-7 End Cover Replacement
End Cover
3-7
Research, Inc.
——WIRING
THERMOSTAT
Figure 3-8 Thermostat Wiring
WIRING FORCED-AIR
BLOWER
3-8
Model 4554 PanellR™ Instruction Manual
heater sr body (Figure 3. 8). The thermostat is is a a feature of the Model 4554 that safe guards
the heater from overheating. The thermostat is rated for 120 volt, 15 amp service. When
properly wired to the heater power control system, the thermostat will “trip” if it reaches a
temperature of (180*F [82*C)) resulting in loss of power to the heater if wired to operate in
this configuration. The thermostat will reset after it cools below a temperature of 150°F
(66°C).
LT Junction
7 “ Box
Thermostat
” Wiring
Ceramic
Reflector
The Model 4554 is typically ordered with the forced-air blower system mounted to the
heater. (The 3 inch (76 mm) versions can only be ordered with the remote mount blower
system kit as an accessory). The blowers are ordered in one of two versions: 115 volt/60
Hz or 230 volt/50 Hz.
The wires of the blower(s) mounted to the back of the Model 4554 run from the blower to
the electrical junction box mounted to the back side of the heater (Figure 3-9). These wires
must be properly joined to the appropriate circuitry before the blower can operate. All
applicable electrical standards and codes must be followed when wiring the forced-air
blower.
Model 4554 PanellR™ Instruction Manual
installation
REMOTE-MOUNT
+— Blower
Blower
N и Wiring
\
A Junction
X + Box
р
<b 7
| “Thermostat
17 Wiring
Model 4554
“— Heater
Installing the Remote-Mount Blower Kit to the Model 4554 heater is a straight-forward,
BLOWER KIT easy procedure. The kit itself contains the following components (Figure 3-10):
+ Blower (one for most kits, two in kits for 38 inch (965 mm) length heaters)
+ Blower Collar (one per blower)
« Flexible Duct (one per blower)
» Heater Collar (one per blower)
« Hose Clamps (two per blower)
» Mounting screws to attach the blower collar to the blower and the heater collar to the
heater
In most cases, it is recommended to install the Model 4554 heater prior to installing the
remote-mount blower kit. Prior to installing the blower, determine the location and
support structure that the blower will be mounted to. Make sure there is adequate room
around this structure or framework that allows the blower to reside unencumbered by any
structure, wiring, or other apparatus.
Once the heater is installed, the remote-mount blower kit is installed as follows:
1. Attach the heater collar to the Model 4554 heater using the existing four 10-32 UNF
screws on the heater.
2. Attach the blower collar to the blower using the four 10-32 UNF screws provided
with the kit.
3. Mount the blower collar/blower assembly to the chosen support structure (see Figure
3-11 for the blower collar mounting hole dimensions and locations).
3-9
Research, Inc. Model 4554 PanellR™ Instruction Manual
MATTE
PENA Y e
Mounting hardware such as screws or bolts and nuts are not provided with this
Kit.
NOTE:
The flexible duct provided with the remote-mount blower kit is 4 feet long (1.2 m).
The blower should be mounted close enough to the heater so the flexible duct can
adequately connect the blower to the Model 4554.
4. Place the hose clamps over the flexible duct — one at each end of the duct.
5. Fit each end of the flexible duct over the corresponding blower and heater collars.
6. Move each hose clamp over the hose to a point approximately half-way on to the
heater collar.
7. Hand-tighten both hose clamps using an appropriate wrench or screwdriver.
NOTE:
The flex duct can be cut as necessary to fit between the heater and the blower. A
duct longer than 4 feet is not recommended.
Figure 3-10 Remote-Mount Blower
Installation
Blower
Blower
Flexible > A
Duct
4' (1.2m)
1
N Heater
Collar
4554 Pyropanei
3-10
Maintenance
Periodic inspection for dirt and contaminants on the heater, blower mechanism, and
lamps, and removal of such, will ensure that the Model 4554 continues to operate
efficiently and will extend lamp life.
In dirty environments or heating operations the lamps may become contaminated by
smoke, dust, fingerprints or other foreign matter. When this occurs it is recommended that
they be cleaned using the following procedure:
4). WARNING
Disconnect all power running to the Model 4554 from the power source and allow
the heater to cool at least five minuets before continuing.
CAUTION
Wear soft, clean, oil-free flannel or plastic gloves when handling quartz lamps.
Skin oils and other contaminants can cause premature lamp failure if they are
allowed to reside on the quartz lamp.
Using a soft, dry cloth or tissue, wipe the residue from contaminated lamps. A solution of
househould strength ammonia and water can be used as a solvent.
The ceramic reflector is made of a high temperature, ceramic material and is essentially
self-cleaning. Surface heat normally prevents contaminant condensation on the reflector.
Increasing power to the lamp for short time periods will increase the heater temperature
resulting in the removal of most contaminates.
4-1
4-2
Operating Instructions
Operation of the Model 4554 is relatively straight-foreward once installed and properly
(electrically) wired to an appropriate power control source. In addition, the forced-air
blower system and heater thermostat must be connected to an appropriate power supply in
order to operate.
The intensity of the infrared energy generated by the lamps is directly proportional to the
amount of electrical power supplied to the lamps. Determining the amount of electrical
power supplied to the lamps in the Model 4554 depends on a variety of parameters
including (but not limited to):
+ Infrared absorptivity of target product (eg. Target material properties including: color,
surface condition, and temperature)
* Desired product heating rate
* Minimum/maximum target product temperature
* Distance from heater to target product
* Speed of target product moving through the heating area
In general, a limited number of experimental tests to determine the optimal settings (i.e.
heater-to-target distance, applied power to the lamps, product target speed through the
heating area, etc.) should be performed for any Model 4554 installation. Following this
approach will yield the best operational settings for a given application.
Depending on the application (and if feasible), a temperature control feed back system
may be used to control the energy output of the Model 4554. A typical control system
includes power control system, temperature measurement capability (ies), target product
tachometer feedback (moving target applications), and alarm/emergency shut down
capability (ies). Employing such a system allows for continuous monitoring of the heating
process and ensures continuous, steady state infrared energy output from the heater.
Beyond routine, periodic maintenance (See Section 4 — Maintenance) and following all
safety practices (See Section 2 — Safety) the Model 4554 requires no additional care or
handling for correct, efficient operation.
5-1
Research, Inc.
Model 4554 PanellR™ Instruction Manual
5-2
Specifications
4554-B-05-03
4554-B-10-03
4554-B-16-03
4554-B-25-03
4554-B-38-03
4554-A-05-06
4554-A-05-12
4554-A-10-06
4554-A-10-12
4554-A-16-06
4554-A-16-12
4554-A-25-06
4554-A-25-12
4554-A-38-06
4554-A-38-12
Dimensions and
Specifications
500T3, 500T3/CL,500T3/CL/HT
1200T3/CL, 1200T3/CL/HT
100073
2000T3/CL/HT
1600T3, 1600T3/CL
3000T3/CL
2500T3, 2500T3/CL, 2500T3/VB/CL
5MT3/1CL/HT
3800T3, 3800T3/CL, 3800T3/VB
3800T3/VB/CL
3800T3/CL/HT/420
500T3, 500T3/CL,500T3/CL/HT
1200T3/CL, 1200T3/CL/HT
1000T3
2000T3/CL/HT
1600T3, 1600T3/CL
3000T3/CL
2500T3, 2500T3/CL, 2500T3/VB/CL
5MT3/1CL/HT
3800T3, 3800T3/CL, 3800T3/VB
3800T3/VB/CL
3800T3/CL/HT/420
6-1
Research, Inc.
Model 4554 PanellR
TM Instruction Manual
——Ordering-Information — Model 4554
Model Product Description
4554 High Density, Area Infrared Heater
Code Lamp Spacing
A 1 inch (25 mm) on center
BO 0.75 inch (19 mm) on center
Code Length
05 5 Inches (127 mm)
10 10 Inches (254 mm)
16 16 Inches (406 mm)
25 25 Inches (635 mm)
38 38 Inches (965 mm)
— Code — Width Ш
030) 3 Inches ( 76 mm)
06 6 Inches (152 mm)
12 12 Inches (254 mm)
Code Blower Kit EE
HB1150) Heater-mounted blower, 115V, 50/60 Hz
HB230@) Heater-mounted blower, 230V, 50/60 Hz
NB No Blower
-— Code Additional Options
ER Edge Reflectors
(1) 3inch (76 mm) width models use four lamps located on 0.75 inch (19 mm) centers.
(2) Heater-mounted blower kits are only available on 6 inch (152 mm) and 12 inch (304 mm) width heaters.
Order Remote-mounted Blower kit for 3 inch (76 mm) wide heaters from 'Accessories/Spare Paris’ list.”
Ordering Example—Model 4554
Lamp Length Width Blower Additional
Spacing Kit Options
Typical Model Number 4554 A 25 06 HB115 ER
6-2
Model 4554 PanellR™ Instruction Manual Dimensions and Specifications
— Accessories, Spare & Replacement Parts—Model 4554
Model Description
Set of two edge reflectors for:
ER-4553/4-05 | 5 Inch (127 mm) length
ER-4553/4-10 | 10 Inch (254 mm) length
ER-4553/4-16 | 16 Inch (406 mm) length
ER-4553/4-25 | 25 Inch (635 mm) length
ER-4553/4-38 | 38 Inch (965 mm) length
Heater-mounted Blower Kit for:
HB115-5-25 5 Inch (127 mm) to 25 inch (635 mm) lengths, 115V, 50/60 Hz
HB115-38 38 Inch (965 mm) length, 115V, 50/60 Hz
HB230-5-25 5 Inch (127 mm) to 25 inch (635 mm) lengths, 230V, 50/60 Hz
HB230-38 38 Inch (965 mm) length, 230V, 50/60 Hz
Remote-mounted Blower Kit for:
R3B115 3 Inch (76 mm) Width, 5 inch (127 mm) to 38 inch (965 mm) lengths, 115V, 50/60 Hz
R3B230 3 Inch (76 mm) Width, 5 inch (127 mm) to 38 inch (965 mm) lengths, 230V, 50/60 Hz
RB115-5-25 6 Inch (152 mm) or 12 inch (304 mm) Widths, 5 Inch (127 mm) to 25 inch (635 mm) lengths,
115V, 50/60 Hz
RB115-38 6 Inch (152 mm) or 12 inch (304 mm) Widths, 38 Inch (965 mm) length, 115V, 50/60 Hz
RB230-5-25 6 Inch (152 mm) or 12 inch (304 mm) Widths, 5 Inch (127 mm) to 25 inch (635 mm) lengths,
230V, 50/60 Hz
RB230-38 6 Inch (152 mm) or 12 inch (304 mm) Widths, 38 Inch (965 mm) length, 230V, 50/60 Hz
Lamps — 4554
Model Heater Length Lamp Description
057540-002 5 Inches (127 mm) 500 50073
057541-001 5 Inches (127 mm) 500 500T3/CL
094312-002 5 Inches (127 mm) 500 500T3/CL@
057541-003 5 Inches (127 mm) 1200 1200T3/CL
057544-003 5 Inches (127 mm) 1200 1200T3/CUHT
057540-003 10 Inches (254 mm) 1000 1000730
057544-002 10 Inches (254 mm) 1000 1000/T3/2CL/HT®
057544-005 10 Inches (254 mm) 2000 2000/T3/CL/HT®
057540-004 16 Inches (406 mm) 1600 1600730
057541-004 16 Inches (406 mm) 1600 1600T3/CL®
057541-008 16 Inches (406 mm) 3000 3000T3/CL®
094312-001 16 Inches (406 mm) 3000 3000T3/CL@
057541-005 25 Inches (635 mm) 2500 2500T3/CL
057549-001 25 Inches (635 mm) 2500 2500T3/VB/CL
057544-008 25 Inches (635 mm) 5000 S5MT3/1CL/HT®
057540-006 38 Inches (965 mm) 3800 3800730
057541-006 38 Inches (965 mm) 3800 3800T3/CLM
057549-002 38 inches (965 mm) 3800 3800T3/VB/CL
057540-007 38 Inches (965 mm) 3800 3800T3/4206)
(1) These lamps are for horizontal operation only.
(2) HeLeN-coated, glare reduction lamp.
6-3
Research, Inc.
TM Instruction Manual
Lighted Overall Overall
Length (LL) Length (A) Width (B)
Inches (mm) Inches (mm) Inches (mm)
4554-B-05-03 5-6 (127-152) 9.38 (238) 3.0 (76)
4554-B-10-03 10 (254) 14.38 (365) 3.0 (76)
4554-B-16-03 16 (406) 20.39 (518) 3.0 (76)
4554-B-25-03 25 (635) 29.38 (746) 3.0 (76)
4554-B-38-03 38 (965) 42.38 (1076) 3.0 (76)
4554-A-05-06 5-6 (127-152) 9.38 (238) 6.0 (152)
4554-A-10-06 10 (254) 14.38 (365) 6.0 (152)
4554-A-16-06 16 (406) 20.39 (518) 6.0 (152)
4554-A-25-06 25 (635) 29.38 (746) 6.0 (152)
4554-A-38-06 38 (965) 42.38 (1076) 6.0 (152)
4554-A-05-12 5-6 (127-152) 9.38 (238) 12.0 (3.5)
4554-A-10-12 10 (254) 14.38 (365) 12.0 (3.5)
4554-A-16-12 16 (406) 20.39 (518) 12.0 (3.5)
4554-A-25-12 25 (635) 29.38 (746) 12.0 (3.5)
4554-A-38-12 38 (965) 42.38 (1076) 12.0 (3.5)
6-4
Model 4554 PanellR™ Instruction Manual
Dimensions and Specifications
Model 4554 Dimensions
All Dimensions in
Inches (mm)
Figure 6-1
6 & 12 Inch (152 & 305 mm) Wide Model 4554
1.25, 1.25
7 an (32) 7
; +
+
Ho000
O „= | ho &
a y 3 +4 o
unt? | VO o
3 O
| o
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E
сос
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e 0.625
(15.9)
+ +
0.75, |. с [10.75
(19) |. A | (19)
Blower
р
Electrical
Junction Box
3 Inch (76 mm) Wide Model 4554
0 &
1.25 125 © ©
| (32) (32) | ©,
fe Ea et
B 4 | S- im rer t—— vestes -5 |
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| k075 (19) 0.75 (19) =| |- о 5;
‘ A ga
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12.5 pm Summ.
(318)
© e
| В |
6-5
Research, inc. Model 4554 PanellR™ Instruction Manual
Figure 6-2 Model 4554 Dimensions
All Dimensions in
Inches (mm)
38 Inch (965 mm) Length Model 4554
30.63 (778)
21.19 (538)
11.74 (298)
©
©
+
| 0.75 (19) 0.75 (19) |
k A y
+ pr < - , pu e ai.
/ С De, BI ower / Km. Bi ower
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Do E и Junction Box Do E 7
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6-6
pren
*
Calculate the percentage of the applied voltage to the lamp’s rated voltage:
DETERMINING THE
CURRENT PER LAMP Percent Voltage = Applied Voltage x 100
Rated Voltage of Lamp
2. Use Fig A-1 to determine the percent of power dissipated by the lamps at that percent
voltage. Or for greater accuracy, calculate the percent of power dissipated:
Percent of Power Dissipated = (Percent Voltage)" 54
3. Determine the power dissipated:
Dissipated Power = Percent of Power Dissipated x Rated Power
4, Calculate the lamp current:
Dissipated Power
Applied Voltage
Lamp Current =
Example: Assume a 3800T3, 3800 watt, 570 volt lamp is to operate in a 440 volt line.
440 Applied Voltage x 100 _ 70,
570 Rated Voltage a
1. Percent Voltage =
2. The percent dissipated power at 77% of rated voltage is about 67%. Or to calculate:
Percent of Power Dissipated = (77) = 66.8% ог 67%
3. Dissipated Power =67% Percent of Power Dissipated x 3800 Watts = 2546 Watts
2546 Watts Dissipated Power
440 Volts Applied Voltage — 5.78 Amperes
4, Lamp Current =
Research, Inc.
ure-A-1—Voltage-And
Temperature
Single-Phase Loads
PERCENT WATTAGE AND PERCENT COLOR TEMPERATURE
400
300
200
100
90
80
70
60
50
40
30
20
Model 4554 PanellR™ Instruction Manual
VOLTAGE AND TEMPERATURE CHARACTERISTICS
OF TUBULAR QUARTZ INFRARED LAMPS
(EXCLUDING ALL HALOGEN CYCLE LAMPS)
PERCENT
COLOR
TEMPERATURE
PERCENT OF RATED VOLTAGE
POWER DISSIPATION VS. VOLTAGE FORMULA
Wa _ f Va \*-54 Wa = Actual Power Dissipated, Watts
Wg (% ) Wa = Rated Power, Watts
Va 54 Va = Lamp Voltage, Actual
Wa = WR (17) Vr = Lamp Voltage, Rated
The line current for single-phase loads can be calculated using one of the following
methods:
Determine the current per lamp. If the applied voltage to the lamps is different,
calculate the lamp current as explained on page A-1.
Determine the number of lamps.
Calculate the line current:
Line Current = Lamp Current x Number of Lamps
Example: Assume quantity 2 Model 4554-A-25-12 using 2500T3 lamps connected to a
480 volt source.
1.
2.
The current per 2500T3 lamp connected to a 480 volt source is 5.2 amperes.
The number of lamps in each Model 4554-A-25-12 is 12. Quantity 2 Pyropanels x 12
lamps = 24 lamps total.
Line Current = 5.2 Amperes x 24 Lamps = 125 Amperes
Model 4554 PanellR™ Instruction Manual
hana Lar no
La A.D Cianla
PIU ML ЭВ ICT 4 IDE UE LI
Input Wiring Diagram
125 AMP
480 V
SINGLE
PHASE
125 AMP
62.4 AMP
TYPICAL (4 LAMPS PER CIRCUIT)
62.4 AMP
AAA, MODEL 4554-A-25-12 SII SNS
(12) 2500T3 LAMPS
ИИ ИИ И ИИ И и
ANN, 30,000 WATTS € 480 VOLTS AAA
62.4 AMP
ИИ ИИ ИИ И МИ И И
ZA MODEL 4554-A-25-12 ИДИ ОИ ОИ
ИИ, (12) 2500T3 LAMPS ИИ ИИ ИИ ИМИ МИ И И
62.4 АМР
Y
AMPERES
PER
CIRCUIT
Ji
CASE GROUND
——Three-Phase-Balanced
Loads
4, Line Current =
PanellR™ Instruction Manual
Model 4554
the case of the Model 4554, there should be an equal number of the same wattage lamps
connected to each phase.
The line current for three-phase loads can be calculated using one of the following
methods:
1. Determine the power dissipated per lamp.
2. Determine the number of lamps.
3. Calculate the total power dissipated in the load:
Load Power = Power Dissipated per Lamp x Number of Lamps
4. Calculate the line current:
Load Power
Line Current = Applied Voltage x 1.73
Example: Assume quantity 3 Model 4554-A-25-12 using 2500T3 lamps connected to a
480 volt source.
1. The power dissipated by a 2500T3 lamp is 2.5 kW, or 2500 watts, when connected to
a 480 volt source.
2. The number of lamps in each Model 4554-A-25-12 is 12. Quantity 3 Pyropanels x 12
lamps = 36 lamps total.
3. Load Power = 2500 Watts Dissipated per Lamp x 36 Lamps = 90,000 Watts
90,000 Watts Load Power
480 Volts Applied x 1.73
= 108 Amperes
Model 4554 PanellR™ Instruction Manual
LINE CURRENT
»
108 AMP
108 AMP
480 V
3 PHASE
TYPICAL (4 LAMPS PER CIRCUIT)
LOAD CURRENT |
108 AMP 62.4 AMP
MODEL 4554-A-25-12
(12) 2500T3 LAMPS
AAA 80.000 WATTS @ 480 VOLTS ИИ
SISI SNS
SAA ANA И
62.4 AMP
LOAD 1
62.4 AMP
NAN MODEL 4554-A-25-12
(12) 2500T3 LAMPS
AAA 80,000 WATTS @ 480 VOLTS AAN
УИ АИ И АИ М
SIS ENG
62.4 AMP
LOAD?
62,4 AMP
ААА MODEL 4554-A-25-12
(12) 250073 LAMPS
SOSA
ИИ ИИ ИИ ИИ |
AAA, 30,000 WATTS E 480 VOLTS A AN
62.4 AMP
LOAD 3
=}
CASE GROUND
Research, Inc. Model 4554 PanellR™ Instruction Manual
| Balannad Thran
crie Dai 111
Load Wiring Diagram
(Single Heater)
Line À
Line B
Line C __.
AA MODEL 4554-A-25-12 ANS SNS NS
ANN (12) 250073 LAMPS ПДД И ИИ
ANA, 30,000 WATTS @ 480 VOLTS ANANANANANANANANAN
Model 4554 PanellR™ Instruction Manual
— — Three-Phase Unbalanced Often itis not possible to connect the lamps in the Model 4554 to make a balanced ] oad In
Loads this case, the three line currents supplying the heater lamps can be calculated as follows: |
1. Determine the number of lamps in each load.
2. Determine the current per lamp..
3. Calculate the load current for each of the three loads based on the number of lamps in
each load and the current per lamp.
Load Current = Lamp Current x Number of Lamps in Load
4. Calculate the line current based on the current of the two loads connected to the line:
Line Current = /FLC? + (FLC x SLC) + SLC?
NOTE:
FLC = First Load Current
SLC = Second Load Current
Example: Assume quantity 2 Model 4554-A-25-12 and quantity 1 Model 4554-A-25-06
using 2500T3 lamps connected to a 480 volt source (see Fig. A-5).
1. Number of Lamps in Each Load:
Load 1 = 12 Lamps
Load 2 = 12 Lamps
Load 3 = 6 Lamps
2. The current per 2500T3 lamp connected to a 480 volt source is 5.2 amperes.
3. Load Current 1 = 5.2 Amperes x 12 Lamps = 62.4 Amperes
Load Current 2 = 5.2 Amperes x 12 Lamps = 62.4 Amperes
Load Current 3 = 5.2 Amperes x 6 Lamps = 31.2 Amperes
4. Line Current | = Square Root of [(Load Current 1 of 62.4 Amperes x Load Current 1
of 62.4 Amperes) + (Load Current 1 of 62.4 Amperes x Load Current 3 of 31.2
Amperes) + (Load Current 3 of 31.2 Amperes x Load Current 3 of 31.2 Amperes)] =
82.3 Amperes
Line Current 2 = Square Root of [(Load Current 2 of 62.4 Amperes x Load Current 2
of 62.4 Amperes) + (Load Current 2 of 62.4 Amperes x Load Current 3 of 31.2
Amperes) + (Load Current 3 of 31.2 Amperes x Load Current 3 of 31.2 Amperes)] =
82.3 Amperes
Line Current 3 = Square Root of [(Load Current 1 of 62.4 Amperes x Load Current 1
of 62.4 Amperes) + (Load Current 1 of 62.4 Amperes x Load Current 2 of 62.4
Amperes) + (Load Current 2 of 62.4 Amperes x Load Current 2 of 62.4 Amperes)] =
108 Amperes
Research, Inc. Model 4554 PanellR™ Instruction Manual
Three-phase Load
Wiring Diagram
LINE CURRENT
82 AMP
82 AMP
480 V
3 PHASE TYPICAL (4 LAMPS PER CIRCUIT
LOAD CURRENT | )
108 AMP 62.4 AMP 62.4 AMP
LAAN NAN ИО АИ SNA NNN
LOAD 1
AAA, MODEL 4554-A-25-12 III
(12) 2500T3 LAMPS SII A
A 30,000 WATTS E 480 VOLTS A ARA
62.4 AMP 62.4 AMP
AAA И LOAD 2
AAA NA
CA, MODEL 4554-A-25-12 SII
AAA (12) 2500T3 LAMPS IIA III
RA 30,000 WATTS @ 480 VOLTS AAA ИИ
SNS SSI SSI И И ОМИ
31.2 AMP
АИИС ОИ И LOAD 3
НИИ ИМО NA
НИИ SSI
MODEL 4554-A-25-6
DY (6) 2500T3 LAMPS SS SSI
AAA 15,000 WATTS @ 480 VOLTS AAA SWISS
i Uh
31.2 AMP
CASE GROUND
A-8
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