Model 5194 User`s Manual - Precision Control Systems, Inc.
Contents
1. LCS a PC OPTION SIDE VIEW 5194 HEATER it CUSTOMER SUPPLIED COULANT FLOW REGULATOR H20 OUT a A 1 8 FPT a O H20 RETURN EA 1 8 FPT Figure 5 1 Typical Model 5194 Installation 106687 001 Rev 2 5 1 53 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 install2. 1 14 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 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 106687 001 Rev 2 7 2
3. 194 02 Quartz Window Kit Model 5194 04 Quartz Window Kit Model 5194 05 Quartz Window Kit Model 5194 10 Quartz Window Kit Model 5194 16 Quartz Window Kit Model 5194 25 Quartz Window Kit Model 5194 38 106587 001 106587 002 103390 002 103390 004 103390 012 103390 008 103390 010 Quartz Halogen Infrared Lamp Ceramic End Seal Model 5194 02 Quartz Halogen Infrared Lamp Ceramic End Seal Model 5194 04 Quartz Halogen Infrared Lamp Ceramic End Seal Model 5194 05 Quartz Halogen Infrared Lamp Ceramic End Seal Model 5194 10 Quartz Halogen Infrared Lamp Ceramic End Seal Model 5194 16 Quartz Halogen Infrared Lamp Ceramic End Seal Model 5194 25 Quartz Halogen Infrared Lamp Ceramic End Seal Model 5194 38 106684 001 034766 001 106686 001 Electrical Power Cable 8 foot 2 4 m length Ceragold End Reflectors set of 2 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 Foot switch for remote start C100 1 KFS 5420 106687 001 Rev 2 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 a
4. 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 Lighted Lamp Length Reflector Length Overall Heater Length 02 1000 04 2000 05 1000 10 2000 16 3000 25 3550 38 3800 2 Inches 51 mm 4 Inches 102 mm 5 Inches 127 mm 10 Inches 254 mm 16 Inches 406 mm 25 Inches 635 mm 38 Inches 965 mm 2 56 Inches 65 mm 2 95 Inches 75 mm 5 Inches 127 mm 11 Inches 279 mm 16 Inches 406 mm 25 Inches 635 mm 38 Inches 965 mm 2 6 Inches 66 mm 4 Inches 102 mm 6 Inches 152 mm 11 Inches 279 mm 16 6 Inches 421 mm 26 Inches 660 mm 39 Inches 990 mm 6 1 Inches 155 mm 7 5 Inches 191 mm 9 5 Inches 241 mm 14 5 Inches 366 mm 20 1 Inches 510 mm 29 5 Inches 749 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 Ordering Example Model 5194 Model 5194 Heating Chamber Length 16 3000 Optional Equipment 03 00 Typical Model Number Accessories Spare amp Replacement Parts Model 5194 Model 106586 001 106586 002 106586 003 106586 004 106586 005 106586 006 106586 007 Description Quartz Window Kit Model 5
5. aning the Reflect f oit teo tad ete e eg 6 4 Section 7 Spare amp Replacement Parts eeeeee eee eene eee ee ee eene eeeeees 771 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 E Soldering E Unsoldering E Drying ink Forming plastic E 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 2779 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
6. are listed below Reference Figures 7 1 7 2 and 7 3 when using this list PART NO DESCRIPTION 5194 02 5194 04 5194 05 5194 10 5194 16 5194 25 5194 38 4 054979 099 PanheadScrew 8 32X5 8___ 8 s 8 8 8 8 8 6 06302 00 Pug 2NPTXI4LG 1 1 1 1 1 1 1 7 100571 004 TerminalBlock 204_________ _ 2 2 2 2 2 2 2 106587 00 LampQIHI20100W 1 T T T 106587000 Lamp QIHI202000W_______ 1 T T 103390 002 Lamp Q40 100w 1 T JJ 103390 004 Lamp QIH2402000W T 1 P 10339 012 LampQrH24o 3000W T T t1 PF 103390 008 Lamp QIH600 5000W________ T T T 1 __103390 010__ Lamp QrH4s0 3300w_ T T T t 9 105830001 Fittting 1 8NPTx 1 4 3 3 3 3 3 3 3 10 11 106594002 EndCastins 1 2 J 2 2 2 2 2 106585 001 End Cover 2 2 2 2 SIC estero DN pp 106606 002_ Reflector 519404 1 T TT 106606 003 JRefletor5194 05 1 T 106606 004 JRefletor5194 10 T T 1 106606 005 Reflector 519416 T T t1 106606 006 Reflector519925 T 1 106606 007 Reflector 5194 38 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
7. ation 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 61 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 6 1 6 2 amp 6 3 Note e Remove all power from the heater BEFORE attempting to install replace the lamp e Allow a minimum of 12 inch 12 mm of slack in the lamp lead so that the lead is not taut when inserted into the lamp terminal block e 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 Remove end cover screws 2 per end cover Remove end covers on both ends of the heater Hoop Figur
8. 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 5194 02 5194 04 5194 05 5194 10 5194 16 519425 5194 38 Weight Pounds kg 2 7 1 2 3 3 14 42 19 6328 8769 1276 7 183 83 Lamp Tepe QIH120 QIH120 QIH240 QIH240 QIH240 QIH600 QIH480 P yP 1000RD2 2000RI2 1000R12 2000R12 3000R12 5000R12 3800R12 Lamp Part Number 106587 001 106587 002 103390 002 103390 004 103390 012 103390 008 103390 010 Pea Inches 556 65 2 95 75 50127 110279 16 0 406 25 0 635 38 0 965 Wa
9. e Linell i Porrares Heaters Series Publication A106687 001 Rev 1 January 2003 Another quality product from OX esearch INC 7128 Shady Oak Road Eden Prairie MN 55344 Phone 952 949 9009 Fax 952 949 9559 E mail sales researchinc com www researchinc com Copyright O 2009 by Research Inc All rights reserved Under copyright laws neither the documentation 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 Additional information regarding application of the Model 5194 heater or other Res
10. e tighten the terminal block set screws to a torque of 0 6 Ft Lbs 0 82 N m 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 Reinstall the quartz window within the heater by carefully sliding the window into the grooves machined into the heater reflector 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 2 6 3 Remove the two end cover screws and the end cover from one end of the heater 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 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 Reinsert the edges of the window into the grooves machined into both sides of the reflector body Gently push the window into the reflector until it is completely seated against
11. e 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 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 10 11 Figure 6 3 Model 5194 Lamp Removal 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 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 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 Tighten the setscrews in each terminal block so the lead wires are held securely Not
12. earch Inc products Ordering additional Research Inc products or Manuals Technical assistance and training Appropriate Contact Your local sales representative Your local sales representative or Research Inc Customer Service 952 949 9009 Research Inc Factory Service 952 949 9009 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 omomososososssssss L I Section 2 Features amp Benefits ccccccccscscscscssssscscscscscscscscscscscssscssscscssscsssescsese 2 L Section 3 SpecifICatiOns o eeiee eoe te oe neon ea eene neo mE Pera eene pe Eee epus rape innu si eror eara J L DIMENSIONS 3 3 5 Asie iene en erae ia 3 2 Ordering Information ii 3 3 Accessories Spare amp Replacement Parts ii 3 3 y OCHO MS ATELY esee onte Arial Section 5 Installation e nolan de 5 1 Un pack and Check for Damage sss ene 5 1 5 2 Mounting the Heater atto ree eer em t d ret do 5 1 5 3 Heater Cooling Connections eese eene enne 5 2 S 4 Electrical Connectiorns n rune tee trt ie Fa e o ER ENTRE de 5 2 6 1 Lamp Removal Replacement Installation essere 6 1 6 2 Quartz Window Cleaning and Replacement eee 6 4 6 3 Cle
13. 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 1s 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 5420 power 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 o amy fa CS o 7 re e 1 RA Ar pp mo e eee o val 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
14. nd 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 ALW AYS disconnect the power lines AND any optional interlock circuits before in
15. stalling or changing lamps NEVER operate the heater with end covers removed 106687 001 Rev 2 4 1 FIRE SAFETY l 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 RESEARCH INC SUPPLIED oen IN
16. the end cover mounted to the heater Reinstall the other end cover and secure with the two end cover screws 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 l 2 Remove the lamp as described in Section 6 1 Lamp Removal Replacement Installation 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 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 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 106687 001 Rev 2 6 4 Section 7 SPARE amp REPLACEMENT PARTS ES MTS P S Identification Figures 7 1 7 2 7 3 Model 5194 Parts 106687 001 Rev 2 Replacement parts for the Model 5194
17. tt Density W in 390 678 200 182 187 5 142 100 Rated Voltage 120 120 240 240 240 480 480 Rated Voltage 1000 2000 1000 2000 3000 3550 3800 Watts Voltage Amps GPM lpm Cooling Air Flow SCFH 30 0 85 300 85 30 0 85 40 1 1 50 1 4 60 1 7 50 1 4 M 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 amp 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 106687 001 Rev 2 3 1 310 32 X 3 4 MOUNTING SCREWS QTY 4 l 0 D COOLING 4 172 NPT 2 TUBING PORT 2 POWER INPUT 4 O D TUBING AIR PORT END VIEWS D OPT sei REFLECTORS 1 75 OPT END 44 5 REFLECTORS Dimension Heater Model Number x B C ut Inches mm Inches mm Inches mm 8 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 11 279 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 26 660 12 7 5 7 5194 38 3800 42 5 1079 39 75 1009 39 990 18 3 8 3 Figure
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