Model 5070 User Manual - Precision Control Systems, Inc.

Model 5070 User Manual - Precision Control Systems, Inc.
MODEL 5070
MULTIZONE HEATER
USER'S MANUAL
Publication KA075725-001A
For Precision Control Systems, Inc./ Research Inc.
7128 Shady Oak Road
Eden Prairie, MN 55344
952-949-9009 Fax number 952-949-9559
www .researchinc.com
APRIL 1990
ow we A A но Е =
Precision Control Systems, Inc./ Research Inc.
7128 Shady Oak Road
Eden Prairie, MN 55344
952-949-9009 Fax number 952-949-9559
www. researchinc.com
KA075725-001A
Model 5070 Multizone Heater User's Manual
TABLE OF CONTENTS
SECTION 1,
GETTING TO KNOW YOUR MULTIZONE HEATER
есио
1.1
1.2
2.1
2.1.1
2.1.2
2.1.3
2.2
2.3
2.4
2.5
3.2
3.2.1
3.2.2
3.2.3
3.3
4.1
4.2
4.2.1
4.2.2
4.3
4.4
4.5
4.5.1
4.5.2
4.6
4.7
HOW THE MULTIZONE HEATER WORKS
SPECIFICATIONS
SECTION 2.
SAFETY
SAFETY
General Safety Practices
Fire Safety
Maintaining Proper Air and Water Pressure
for Cooling
UNPACK AND CHECK FOR DAMAGE
WHERE TO SET UP THE MODEL 5070
POWER NEEDS
CLEANING THE HEATING CHAMBER
SECTION 3,
LATI
HOW TO WIRE THE HEATER TO A POWER
CONTROLLER
Introduction
Balancing Tungsten Filament Quartz Lamp
Loads
COOLING
Connections for Water Cooling
Connection for Air Cooling
Connection for Specimen Cooling Via Inert
Gas or Air
AIR PRESSURE TAP
SECTION 4,
BLESHOOTING
INTRODUCTION
REPLACING PARTS OF THE MULTIZONE
HEATER
Parts List and Ordering Information
Returns
TOOLS AND TEST EQUIPMENT
RECOMMENDED SPARE PARTS LIST
REPLACING PARTS
Lamps
Replacing the Quartz Window
CLEANING THE REFLECTOR
SHIPPING LIST
4-1
4-1
4-1
4-1
4-1
4-1
4-1
4-2
4-3
.+...
LIST OF ILLUSTRATIONS
Figure Title Page
1-1 Model 5070, front side 1-1
1-2 Model 5070, rear side 1-1
3-1 Lamp wire numbers for connection to a power
controller 3-1
3-2 Zone/wire configuration (Model 5070-3 shown) 3-1
3-3 Model 5070, rear side, showing air, water, and
gas inputs 3-2
34 Airinput exhaust holes for specimen cooling 3-2
4-1 Removing the lamp terminal access cover 4-1
4-2 Top of heater, access cover removed 4-2
4-3 R- Changing a lamp 4-2
4-4 Removing the quartz window 4-3
LIST OF TABLES
Table Iitle — Page
1-1 Specifications for the Model 5070 Multizone 1-2
Heater a
1-2 Minimum Air and Water Flow Requirements 1-2
for the Model 5070
KA075725-001A
SECTION 1.
GETTING TO KNOW YOUR MULTIZONE HEATER
1.1 HOW THE MULTIZONE HEATER
WORKS
The Research, Inc. Model 5070 Multizone Heater (figures
1-1 and 1-2) consists of a heater unit with the following major
components :
1. Q1000 T3/4CL infrared lamps
2. Wiring harness
3. Clear quartz window
4. Specular aluminum, water-cooled reflector
5. Air pressure tap: 10-32NF to 1/8 hose
The 5070 heater can heat specimens up to 2.5 inches
(63.5 mm) wide and from 1.20 inches (Model 5070-1) to
14.40 inches (Model 5070-12) long.
Each zone in the heater contains two infrared lamps, and
can be individually controlled by an external controller, The
wiring harness identifies each zone by number, and each lamp
within a zone by the letter A or B.
Lamp envelopes, the quartz window, and lamp end seals are
air cooled. The reflector body and heater frame are cooled by
water. A gas port on the rear side of the heater offers the
capability of using air or an inert gas to accelerate specimen
cooling.
For more information about product support, contact your
customer service engineer at Research, Inc. His or her tele-
phone number in the United States is (612) 941-3300.
ZONE 1, LAMP A
ZONE 1, LAMP B
WIRE C FOR
SEPARATE CONTROL
Ц 4 A 1A O
Fae TE Pars NE
>. ET M SE
OF LAMPS IN ZONE 1
QUARTZ WINDOW
RETAINER CLIP
QUARTZ WINDOW
RETAINER CLIP
1747
HOT EXHAUST
AIR QUTLETS
WATER
INPUTS
GAS
INPUT
AIR
PRESSURE
TAP PORT
COOLING
AIR INPUT
1746
Figure 1-1. Model 5070, front side.
KA075725-001A
Figure 1-2. Model 5070, rear side.
1-1
Getting to Know Your Multizone Heater
1.2 SPECIFICATIONS
The Model 5070 specifications are shown in tables 1-1 and
nual
1-2,
Table 1-1. Specifications for the Model 5070 Multizone Heater
(A) (B)
MODEL NO. OF NUMBER POWER CHAMBER OVERALL
NUMBER ZONES OF LAMPS MAX. KW HT., INCHES HT., INCHES
5070-1 1 2 2 1.20 2.70
5070-2 2 4 4 2.40 3.90
5070-3 3 6 6 3.60 5.10
5070-4 4 8 8 4.80 6.30
5070-5 5 10 10 6.00 7.50
5070-6 6 12 12 7.20 8.70
5070-7 7 14 14 8.40 9.90
5070-8 8 16 16 9.60 11.10
5070-9 9 18 18 10.80 12.30
5070-10 10 20 20 12.00 13.50
5070-11 11 22 22 13.20 14.70
5070-12 12 24 24 14.40 15.90
NOTE
Maximum heat flux density at the specimen (target) surface is .44 KW per inch? Maximum allowable
specimen (target) temperature is 1454°C (2650°F) where specimen absorptance is greater than .5.
Table 1-2. Minimum Air and Water Flow Requirements for
the Model 5070*
NOTES
MODEL AIR WATER
NUMBER CFM GPM
5070-1 6 .06
5070-2 12 12
5070-3 18 18
5070-4 24 24
5070-5 30 .30
5070-6 36 .36
5070-7 42 42
5070-8 48 48
5070-9 54 ‚54
5070-10 60 ‚60
5070-11 66 ‚66
5070-12 72 ‚72
*More than the minimum coolant flows are recommended and
as a result will enhance component life and performance.
1-2
KA075725-001A
SECTION 2.
SAFETY
Model Multi r
21 SAFETY
2.1.1 General Safety Practices
1. Always wear safety glasses when using the Model 5070
Heater to provide protection from infrared radiation.
2. Use gloves when handling specimens because the speci-
mens can be hot enough to cause severe burns.
Hot exhaust air leaving the heating
chamber can get as hot as 230°C (446°F).
Keep hands away from the region of the
hot air exhaust ports while the heater is
operating or serious injury due to burns
may result.
2.1.2 Fire Safety
1. Obey the same fire-safety rules you observe when you
work with hot plates, high intensity infrared heaters,
propane or acetylene torches, soldering irons, and other
equipment that gets very hot.
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 fires from all the types of material
near the Model 5070 Heater.
2.1.3 Maintaining Proper Air and Water
Pressure for Cooling
Be sure to have sufficient air and water pressures to meet
the specifications listed in table 1-1 for the model heater which
you are using. Failure to do so could result in overheating and
damage to the unit.
KA075725-001A
For example, if cooling air is insufficient, the quartz lamp
envelopes may soften and distort, and lamp endseals and insula-
tors located in the exhaust endseal chamber are likely to fail
prematurely.
If cooling water is insufficient, the O-ring seals for the water
passages will fail and the risk of catastrophic meltdown is likely.
2.2 UNPACK AND CHECK FOR DAMAGE
1. Take the Model 5070 Heater out of its shipping container.
2. Check the heater unit for shipping damage. If you find
damage:
A. Keep the shipping container and packing material.
B. File a damage claim with the shipper who delivered
the Model 5070 Heater to your company.
2.3 WHERE TO SET UP THE MODEL 5070
The Model 5070 Heater can be used on a flat, level surface
made of firebrick or similar fireproof material.
Consider doing setups in a load test machine, and on a special
stand on a workbench. Also consider mounting the unit in a
processes machine.
2.4 POWER NEEDS
The Model 5070 Heater uses up to 240 volts RMS. All models
come with lamp power wires labeled for proper connection to an
external controller. See section 1.2 for complete power specifi-
cations.
2.5 CLEANING THE HEATING CHAMBER
Before turning on the heater, be sure the quartz window is
clean. Use anon-abrasive glass cleaner and a clean, dry, lint-free
cloth to remove any smudges or debris:
1. Be sure the heater controller 1s OFF.
2. Let the heater cool down to room temperature before
commencing cleaning operations.
2-1
SECTION 3.
INSTALLATION
3.1 HOW TO WIRE THE HEATER TO A
POWER CONTROLLER
3.1.1 Introduction
Model 5070 Muluzone Heaters are wired at the factory for
easy installation with a power controller. Each zone has two
lamps wired in series (figure 3—1). Each lamp wire in the wiring
harness 1s labeled with a zone number and the letter A or B
(figure 3-2).
NOTE
The first and last zones In the heater have a
third wire labeled with the zone humber and the
letter C (figure 3—1 shows a Model 5070-3, so
zones 1 and 3 have a C wire). This wire may
be used to provide separate control for each
lamp in those zones.
PA __
| a T
i
| Т NE T
| —— 1A
| 1 No
| 1B
| E,
AY y 1C
| THERMOSTAT: 4 oA
| OPEN AT DT
255°F 2 o
| CLOSE AT a 2B
| 185°F LAMPS Е
i
| —, 3A
| ZONE 3 o]
NUMBER | ЗВ
| —— 3C
| || — I G
E
1750
3.1.2 Balancing Tungsten Filament Quartz
Lamp Loads
Although lamps are designed for standard line voltages,
current flow through the lamp must be accounted for during its
heatup to operating temperature. The resistance of a lamp
element may be 15 times lower at room temperature than it is at
operating temperature. A lamp element has very little mass
and heats up quickly. Output signal conditioning, which is avail-
able on quality SCR power controllers, provides a ramping of
the output voltage from 0 to operating level in two to three
seconds. This amount of time is considered adequate to bring
the resistance of the element high enough to be within the rating
of the power controller.
CAUTION
The maximum allowable voltage across
the two lamps wired in series in each
zone is 240V.
ZONE 1, LAMP A
ZONE 1, LAMP B
WIRE C FOR
SEPARATE CONTROL
OF LAMPS IN ZONE 1
ATI
A 18 |
QUARTZ WINDOW
RETAINER CLIP
ZONE 1
ZONE ?
ZONE 3
QUARTZ WINDOW
1747 RETAINER CLIP
Figure 3-1. Lamp wire numbers for connection to a
power controller.
KA075725-001A
Figure 3-2. Zone/wire configuration (Model 5070-3
shown).
3-1
Installation
3.2 COOLING
3.2.1 Connections for Water Cooling
WARNING
Clean cooling water is required for safe
operation of the heater. Operating the
heater without water cooling will cause
heater destruction and may be a hazard to
the operator and product.
The reflector body and unit frame of the Model 5070 are
water cooled. The water input and output are on the rear side of
the unit (figure 3-3). Either port may be used as the input.
The two water inputs are tapped for 1/4-18 NPT connectors.
Water pressure should be between 25 and 150 PSIG. Recom-
mended water flow rates are different for different sized units,
depending on the number of lamp zones. Refer to table 1—2 for
the minimum recommended flow rate for your unit.
HOT EXHAUST
AIR OUTLETS
A AIR
не / X : x \ Brg 8 PRESSU RE
‘ is ¡NACIO ire ion Ries TAP PORT
AIR INPUT
Lamp envelopes, the quartz window, and lamp end seals
are air cooled. On Models 5070-1 through -8, there is one air
input tapped for a 1 1/4-11 1/2 NPT connector (figure 3-3).
Models 5070-9 through -12 have two air inputs of this size.
Clean cooling air at a temperature of 55°C (100°F) or cooler
must be supplied. Recommended air flow rates are different
for different sized units, depending on the number of lamp
zones. Refer to table 1-2 for the minimum recommended
flow rate for your unit.
Air exhausts through several output ports on the rear side of
the unit (the number of exhaust ports depends on the number of
lamp zones in the unit). These exhaust ports must be unob-
structed for proper cooling of the lamps and end seals. See
figure 3-4.
WARNING
Hot exhaust air leaving the heating
chamber can get as hot as 230°C (446°F).
Keep hands away from the region of the
hot air exhaust ports while the heater is
operating or serious injury due to burns
may result.
1746
Figure 3-3. Model 5070, rear side, showing air, water, and
gas inputs.
3.2.2 Connection for Air Cooling
WARNING
Clean cooling air is required for safe
operation of the heater. Operating the
heater without air cooling can cause over-
heating of the quartz lamps and insulators,
producing premature failure. Also, it may
be a hazard to the operator and product.
3-2
AIR INPUT
EXHAUST
HOLES
1763
Figure 3-4. Air input exhaust holes for specimen cooling.
KA075725-001A
Model 5070 Multi Г. Installation
3.2.3 Connection for Specimen Cooling
Via Inert Gas or Air
A gas input 1s provided on the rear side of the unit to be used
for inert gas or air for specimen cooling (figure 3-3). Specimen
cooling is accomplished when the gas exhausts through ports in
the heating chamber. The gas input is tapped for a 1/4-18 NPT
connector.
3.3 AIR PRESSURE TAP
The Model 5070 has an air pressure tap on the rear side
(figure 3-3). A barbed fitting for connecting a 1/8-inch hose to
the tap is included with the heater when it is shipped.
NOTES
KA075725-001A 3-3
SECTION 4.
TROUBLESHOOTING
4.1 INTRODUCTION
Sections 4.5,4.6,and 4.7 will tell you how to clean or replace
parts.
Before you check for problems, turn the power controller
OFF and make sure all wires inside both the control unit and
the heater unit are connected properly. A loose wire may be the
only problem. If all the connections look good, then you can
begin checking the items in the table.
4.2 REPLACING PARTS OF THE
MULTIZONE HEATER
4.2.1 Parts List and Ordering Information
Section 4.4 lists spare parts for the Model 5070. If you need
any parts, call our customer service department. The telephone
number in the United States is: 1-612-941-3300.
4.2.2 Returns
If you have to return the Model 5070 or one of its parts to
Research, Inc. for repair or replacement, please do these two
things:
1. Call our field service department at 1-612-941-3300 and
request an authorization to return the material. You will
be given a return material authorization (RMA) number.
2. Return the unit or part to:
Research, Inc.
RMA #
6425 Flying Cloud Drive
Eden Prairie, MN 55344, USA
4.3 TOOLS AND TEST EQUIPMENT
You will need these tools arid test equipment tu replace parts
on the Model 5070:
1. Philips screwdriver to remove the access cover and the
quartz window hold-down bracket.
2. Long-nose pliers or forceps to remove lamps.
3. Lampinsert tool to retract the spring-loaded lamp contact
electrode. This tool is provided with the unit (RI part no.
075978-001).
4. Tissue or clean, lint-free cotton gloves to prevent lamp
envelope contamination.
KA075725-001A
4.4 RECOMMENDED SPARE PARTS LIST
We suggest that you keep the following spare parts on hand.
To order extra parts, see section 4.2.1.
1. Q1000 T3/4CL infrared lamps.
2. (Quartz window.
4.5 REPLACING PARTS
4.5.1 Lamps
See figures 4—1 through 44.
1. Disconnect all power to the unit.
Remove the lamp terminal access cover located at the air
and power input side of the unit (figure 4-1):
A. Loosen the #8 philips head screws.
B. Slide the cover toward the front of the unit and press
down until the other end lifts away from the unit
enough to remove.
C. Slide the cover out of the unit,
B. SLIDE THE PLATE TOWARD THE SCREWS
AND THEN PUSH DOWN ON THE PLATE
UNTIL THE OTHER END CLEARS THE FAR SIDE.
SCREWS
—
о
A. LOOSEN VA
PHILIPS N o
C. GRASP LIFTED EDGE AND
SLIDE PLATE OUT.
1751
Figure 4-1. Removing the lamp terminal access cover.
4-1
Troubl |
3. Remove the Q1000T3/4CL, 1000W, 120V lamps from
their protective containers in such a way that the clear
quartz envelopes remain free from contaminating finger
oils (use a clean tissue or clean, lint-free cotton gloves).
NOTE
This unit will also accept lamp part number
Q500T3/Cl/6, 500W, 120V lamps.
4, Secure the heater to a fixed frame or bracket so that the
unit will not slip during lamp electrode holder retraction.
5. Retract the lamp electrode holder using the lamp insert
tool provided with the unit (figures 4-2 and 4-3).
LAMP
ELECTRODE
FINGERS, т
SPRING-LOADED In “0
LAMP
TERMINALS
1749
Figure 4-2. Top of heater, access cover removed.
LAMP INSERT TOOL
1752
Figure 4-3. Changing a lamp.
4-2
10.
11.
Model 5070 Multizone Heater User's Manual
Insert the new lamp into the heater while the holder is
retracted in such a way that the far end rests on 1ts fixed
electrode contact pin. Some practice may be required to
assure that the far electrode electrical contact is made.
Slowly release the retracted electrode holder onto the
lamp electrode.
Visually inspect electrode seating into the lamp contact
recesses. The lamp axis and electrode axis should be
aligned for good electrical contact. If they are not aligned,
repeat the installation procedure. If the axes are still
not aligned, try a different lamp.
Install all remaining lamps using the same procedure.
CAUTION
All lamp sockets must be filled in order
to have adequate cooling air flow past
all operating lamps. Therefore, if non-
operating lamps are desired, insert a
lamp with a burnt out filament into the
desired position.
Replace the lamp terminal access cover.
Reconnect the power.
CAUTION
Do not operate the Model 5070 heater
without adequate cooling air and water
(see drawing TD075909, Revision 4).
Refer to table 1-2 for minimum air and
water flow rates for your unit.
NOTE
inner shields between lamp zones provide
additionalzone separation ifdesired. However,
the separation Is galned at the expense of
heaterefficlency. Therefore, shields should not
be used unless necessary.
4.5.2 Replacing the Quartz Window
See figure 44.
1.
2.
3.
4.
Disconnect power to the unit.
Loosen the two #8 philips head screws on the window
retainer bracket and lower the bracket.
Remove the old quartz window.
Insert a clean, uncontaminated clear quartz window into
the window groove in the heater unit.
CAUTION
Use aclean tissue or clean, lint-free cotton
gloves to handle the window in order to
prevent contamination from finger prints,
which can cause quartz devitrification.
KA075725-001A
1. LOOSEN THE
TWO PHILIPS
SCREWS.
2. PUSH BRACKET
AGAINST BLOCK,
AS SHOWN.
(x))|| 4—3. SLIDE WINDOW
RÉ OUT OF THE
RETAINER GROOVES
UNTIL IT CLEARS
THE UNIT.
1748
Figure 4-4. Removing the quartz window.
5. If desired, insert a 2.50 inch ceramic fiber seal strip
(provided with the unit) into the window seal grooves.
6. Raise the window retainer bracket and tighten the two #8
philips head screws.
4.6 CLEANING THE REFLECTOR
A clean reflector provides the greatest radiant unit effi-
ciency. If the reflector surfaces become contaminated for some
reason, they reflect less radiant energy out of the emitter opening
of the radiant unit. The energy that does not emit from the unit
must be absorbed by the unit itself, and removed from the unit
by the cooling water and air. This lost energy is wasted heat.
Therefore, if the reflector surfaces become excessively
contaminated, remove the quartz window to gain access to the
heater cavity. In some cases, the lamps must also be removed
to adequately expose the reflector surfaces for cleaning.
The cleaning method will depend on the type of contami-
nation:
1. Dust: Remove with a feather duster or soft-bristled brush.
2. Film: Wipe with a very soft tissue or lint-free cotton cloth
which has been moistened with a mixture of household
ammonia and warm water. The soft tissue or cloth is
necessary to prevent scratching the specular aluminum
reflector surface.
3. Coating: Select a solvent that dissolves the coating
and use the same procedure as used for removing a film
(step 2 above). If this fails to remove the coating, the
unit should be partially disassembled to repolish the
surfaces.
KA075725-001A
NOTE
Before employing any of the above cleaning
procedures, it is advisable to experiment with
it on a small scale In order to verify success
and prevent possible damage to the unit.
If there are questions, please contact:
Research, Inc.
P.O. Box 24064
Minneapolis, MN 55424, USA
(612) 941-3300
4.7 Shipping List
The following items are normally shipped unassembled
with the Model 5070 heater:
1 Lamp Insertion Tool 1
(part # 075928-001)
2 Lamp#Q1000T3/4CL 2/zone
3 Inner Zone Shield 1/zone
(part #075990-001)
4 Window, Clear Quartz 1
(part #075971-___))
5 Window Seal Material 10"
6 Air Pressure Tap: 10-32NF to 1/8 hose 1
7 Instruction Manual 1
NOTES
4-3
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