ControlIR Model 5420 User Manual
Contents
1. 9 3 amp 600 volt Time Delay Fuse 086445 002 11 Transformer 25 VA 099390 001 15 Model 5420 ControlIR M User Manual Model 5420mA Research Inc Spare Parts ltem Description Part Number 1 150 k Ohm Potentiometer 067156 003 2 Solid State Relay Kit 107593 004 3 Two Position Rocker Switch 106820 003 4 Knob with White Pointer 055770 001 5 Terminal Strip 107353 001 6 Line Cord and Plug 086822 001 10 4 20 mA Receptacle 083618 002 Item Description Part Number 1 1 Meg Ohm Potentiometer 067156 001 2 Solid State Relay Kit 107593 004 3 Two Position Rocker Switch 106820 003 4 Knob with White Pointer 055770 001 5 Terminal Strip 107353 001 6 Line Cord and Plug 106821 003 10 4 20 mA Receptacle 083618 002 Item Description Part Number 1 1 Meg Ohm Potentiometer 067156 001 2 Solid State Relay Kit 107593 005 3 480 VAC 20 amp 2 Pole Switch 107406 001 4 Knob with White Pointer 055770 001 5 Terminal Strip 107353 001 6 Line Cord and Plug 103570 002 8 Black Switch Handle 107406 002 9 3 amp 600 volt Time Delay Fuse 086445 002 10 4 20 mA Receptacle 083618 002 11 Transformer 25VA 099390 001 16 Model 5420 ControlIRTY User Manual Spare Parts Model 5420 480 VAC Research Inc 172. ControlIR TM User Manual Load Wiring Connections Research Inc Installation Installation Connect the load wiring as follows 1 ph Unplug the Model 5420 from the power source Remove the 4 screws that secure the cover to the base 2 of the screws are on the back of the 5420 where the cord exits the base and the other 2 are on the bottom next to the front feet Carefully lift the cover up and tilt toward the front of the unit Note There are wires that connect the components on the cover to the components on the base Strip the insulation back on the heater wires 4 inch Insert the wire from the heater through the strain relief Connect the heater wires to the LOAD CONNECTION terminal block Many of Research Inc heaters use a High Temperature Teflon wire that gets connected as follows Black L1 White L2 Red GND Finish the installation by tightening the strain relief around the heater wires and installing the cover back on the base with the 4 screws DO NOT OPERATE WITHOUT COVER PROPERLY INSTALLED LOAD CO NEC sua Model 5420 ControlIRTY User Manual Installation Model 5420mA To connect the wires for the 4 20mA input on the Model 5420mA Control Wiring unit follow these steps 1 Remove the 90 connector from the top of the 5420mA 2 Remove the 1 larger screw to take the connector apart 3 Install wires through the rubber strain relief on the top half of the connector Loosen the 2 scre
3. Model 5420 User s Manual Controlll i SCR Power Controllers les Ser Publication 107399 001 Rev 1 May 2005 Another quality product from RESEARCH INC PROVIDING CONTROLLED ENERGY DRYING 4 CURING 4 HEATING 7128 Shady Oak Road Eden Prairie MN 55344 Phone 952 949 9009 Fax 952 949 9559 E mail info www_recearchine cam Dear Valued Customer Thank you for purchasing a Model 5420 ControlIR power controller We believe it is the finest power controller 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 5420 power controller 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 5420 Requirement Additional information regarding application of the Model 5420 system or other Research 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 SA erry Ni igen Terry Nigon Pre
4. d heaters It is available for 120 240 and 480 volt control with an 8 foot power cord Control features are either a manually set potentiometer a manually set potentiometer with timer or a 4 20mA external control signal The 5420 uses a phase angle fired Solid State Relay SSR to provide precise voltage control to the heater Configured with an ON OFF power switch and a one turn potentiometer to adjust the voltage to the heater Configured with an ON OFF power switch one turn potentiometer and a timer with an integral start switch Configured with an ON OFF power switch and a connector for a user supplied remote 4 20 mA command signal The output voltage to the heater increases linearly to the input milliamp signal 4 mA 0 output voltage 8mA 25 output voltage Model 5420 ControlIR User Manual Description Dimensions 120 and 240 VAC Model 5420 Model 5420E Model 5420mA 480 VAC Model 5420 Model 5420E Model 5420mA Research Inc i 5 7 06 O a 5420 COTTA 8 13 i 6 Lug 06 5220 Creem mi 10 06 a 472 ALS _ 472 Model 5420
5. he timer will flash while the timer is counting down WARNING Infrared heaters can get extremely hot do not leave them operating unattended Always turn the power switch off when shutting the unit down do not rely on setting the power to 0 Research Inc 7 Model 5420 ControlIRTY User Manual Operation Model 5420E Timer Settings Research Inc The timer has 6 different range settings 0 5 seconds 0 50 seconds 0 5 minutes 0 50 minutes 0 5 hours and 0 50 hours The primary range is displayed below the green push button as sec min or hrs The secondary range is displayed as a decimal point between the 1 5 numbers and the zero that follows Example 1 0 or 10 Changing the primary and secondary range settings is done by inserting a screwdriver in the hole on the front side of the 5420 just below the top edge A flat blade or 2 Philips blade screwdriver will work There are 2 positions for each primary range sec sec one is for the 0 5 secondary range the other is for 0 50 secondary range Model 5420 ControlIR TM User Manual Operation Model 5420mA Model 5420mA Power Controller The Model 5420mA requires an external 4 20mA signal to operate This unit will work with PLC s and other programmable controllers to start and stop the heating cycle as well as regulate the output voltage during the cycle 1 Plug the unit in to the appropriate power source 120V 240V 480V 2 Turn the po
6. search Inc 10 Model 5420 ControlIRTY User Manual Maintenance Schematics LINE CORD Model 5420 SWITCH 120 240 VAC LOAD CONNECTIONS Ll L2 GND YL Ww LINE CORD SWITCH 480 VAC LOAD CONNECTIONS LI GRN YLW Research Inc 11 Model 5420 ControlIR TM User Manual Maintenance Schematics Model 5420E 120 240 VAC 480 VAC Research Inc LINE CORD SWITCH LOAD CONNECTIONS Ll Le GND LINE CORD SWITCH LOAD CONNECTIONS Li Le GND 12 Model 5420 ControlIRTY User Manual Schematics Model 5420mA 120 240 VAC 480 VAC Research Inc SWITCH Maintenance CONNECTOR LOAD CONNECTIONS L1 Le GND SWITCH GRN YLW CONNECTOR LOAD CONNECTIONS Li Le GND 13 Model 5420 ControlIR M User Manual Spare Parts Model 5420 Research Inc Spare Parts ltem Description Part Number 1 150 k Ohm Potentiometer 067156 003 2 Solid State Relay Kit 107593 001 3 Two Position Rocker Switch 106820 003 4 Knob with White Pointer 055770 001 5 Terminal Strip 107353 001 6 Line Cord and Plug 086822 001 Item Description Part Number 1 t Meg Ohm Potentiometer 067156 001 2 Solid State Relay Kit 107593 002 3 Two Position Rocker Switch 106820 003 4 Knob with White Pointer 055770 001 5 Terminal S
7. sident Research Inc Model 5420 ControlIR M User Manual Contents Section Page SAFETY cu en EN a ara 1 DESCRIPTION y 2222444442 2 Dimensions 3 INSTALLATION Load Wiring Connections 4 Control Wiring Connections 5420mA 3 OPERATING INSTRUCTIONS da a AAA AA te 6 Model 5420E LLL LLL 7 dimer Seting TOT TTT TO 8 Model 5420mA ss LLL 9 MAINTENANCE AND TROUBLE SHOOTING oo 9 9 9h 9 hh 10 Schematics Model 5420 11 Schematics 54201 02222 222 2224244 12 Schematics Model 5420mA 13 SPARE PARTS LIST Model SA m rca penare vo O 14 Model S4 OB or erede te otero restes lla tir rie iero ei 15 Model 5420mA sissies 16 Exploded Parts View 17 Model 5420 ControlIR TM User Manual Safety Safety General The Model 5420 Power Controller 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 manual and follow these warnings to help prevent accident or injury Electrical fi There is a danger of electrical shocX vvhen servicing this povver controller or the attached Safety MO E heating unit Always disconnect the power cord when servicing the power controller or the heating unit Never operate the 5420 power controller with the cover removed or with the heating unit cover removed The covers have been design to protec
8. t the operator from the high voltage present inside the unit WARNING Always disconnect the power cord when servicing the power controller or the connected heater WARNING NEVER operate the power controller with the cover removed or the heater cover removed Heater The heating unit connected to the 5420 also requires special safety precautions Parts of Safety the various heating units may exceed 500 F 260 C Contact with the lamps reflector or metal parts near the lamps can cause severe burns 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 Research Inc 1 Model 5420 ControlIRTY User Manual Description Model 5420 Model 5420E Model 5420mA Research Inc Model 5420E Description Model 5420 Power Controller Model 5420 The Model 5420 ControlIR is a 15 amp power controller designed to control the voltage supplied to one of the many Research Inc single lamp infrare
9. trip 107353 001 6 Line Cord and Plug 106821 003 Item Description Part Number 1 1 Meg Ohm Potentiometer 067156 001 2 Solid State Relay Kit 107593 003 3 480 VAC 20 amp 2 Pole Switch 107406 001 4 Knob with White Pointer 055770 001 5 Terminal Strip 107353 001 6 Line Cord and Plug 103570 002 8 Black Switch Handle 107406 002 14 Model 5420 ControlIR M User Manual Model 5420E Research Inc Spare Parts ltem Description Part Number 1 150k Ohm Potentiometer 067156 003 2 Solid State Relay Kit 107593 001 3 Two Position Rocker Switch 106820 003 4 Knob with White Pointer 055770 001 5 Terminal Strip 107353 001 6 Line Cord and Plug 086822 001 7 nterval Timer with Push Button 107407 001 Item Description Part Number 1 150 k Ohm Potentiometer 067156 001 2 Solid State Relay Kit 107593 002 3 Two Position Rocker Switch 106820 003 4 Knob with White Pointer 055770 001 5 Terminal Strip 107353 001 6 Line Cord and Plug 106821 003 7 nterval Timer with Push Button 107407 001 Item Description Part Number 1 1 Meg Ohm Potentiometer 067156 001 2 Solid State Relay Kit 107593 003 3 480 VAC 20 amp 2 Pole Switch 107406 001 4 Knob with White Pointer 055770 001 5 Terminal Strip 107353 001 6 Line Cord and Plug 103570 002 7 nterval Timer with Push Button 107407 001 8 Black Switch Handle 107406 002
10. wer switch on 3 Set the power level by supplying a 4 20mA signal from an external source 4 mA 0 output 20 mA 100 output WARNING Infrared heaters can get extremely hot do not leave them operating unattended Always turn the power switch off when shutting the unit down do not rely on setting the power to 0 Research Inc 9 Model 5420 ControlIRT User Manual Maintenance Maintenance and Trouble Shooting Maintenance No routine maintenance is required The 5420 should be kept clean and dry If cleaning is required unplug unit before cleaning Troubleshooting Troubleshooting should be done by Qualified Personnel especially if the 5420 needs to be opened up Heater will not turn on unit is plugged into an energized receptacle on off switch is in the On position On 5420 and 5420E versions with potentiometer control verify control is not set to 0 On 5420E make sure the timer is not set to 0 when pressing the green button additionally the red LED should be flashing as the timer counts down Heater properly connected to the 5420 Lamp burned out in the heater 480 volt 5420E and 5420mA check fuses Heater will not turn off Shorted SCR unit always runs at 100 power Can be checked with unit unplugged open unit disconnect heater wires and put an ohm meter across L1 and L2 if it reads 0 or a small value the SCR is defective On the 5420E check for the correct time range and LED flashing Re
11. ws of the cable clamp and slide the cable through 4 Strip the wires and solder into pins 1 and 3 Pin 1 is pin 3 is 5 Reassemble the connector when complete tightening the cable clamp when complete Research Inc 5 Model 5420 ControlIR TM User Manual Operation Operation Model 5420 Model 5420 Power Controller The operation of the basic Model 5420 is simple once the heater has been connected 1 Plug the unit in to the appropriate power source 120V 240V 480V 2 Turn the power switch on 3 Set the power level from O to 10090 using the potentiometer black knob WARNING Infrared heaters can get extremely hot do not leave them operating unattended Always turn the power switch off when shutting the unit down do not rely on setting the power to 0 Research Inc 6 Model 5420 ControlIRTY User Manual Operation Model 5420E Model 5420E Power Controller The operation of the Model 5420E is simple once the heater has been connected 1 Plug the unit in to the appropriate power source 120V 240V 480V 2 Turn the power switch on 3 Set the power level from 0 to 100 using the black knob 4 Set the heater ON time on the timer by turning the clear plastic dial with the red pointer See Timer Settings section of the manual for more information on the timers range settings 5 Press the green button on the timer to start the timer The red LED on t
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