Model 4069E User`s Manual - Precision Control Systems, Inc.
Contents
1. Research Inc Page 7 of 26 Model 4069E ExtrudeIR Instruction Manual Operating Instructions Single Chamber 2 Inch Diameter Profile Model 4069E 12R 10L 4069E 12R 16L Power Generated 12kW 19 2kW Voltage 240 volt 3 phase 240 volt 3 phase Max Current 29 amp 46 amp Breaker size 50 amp 60 amp Lamp Type 103390 003 103390 005 Water Flow Requirement 1 2 gpm 4 5 lpm 6 8 gpm 12 9 lpm Model Power Generated Voltage Max Current Breaker Size Lamp Type Water Type Flow Requirement Research Inc 4069E 12R 25L 4069E 12R 38L 30kW 45 6kW 480 volt 3 phase 480 volt 3 phase 36 amp 55 amp 50 amp 70 amp 103390 007 103390 010 2 8 gpm 10 6 Ipm 4 2 gpm 15 9 Ipm Dual Chamber 2 Inch Diameter Profile 24Kw 480 volt 3 phase 30 amp 50 amp 103390 003 2 4 gpm 18 Ipm 4069E 12R 10L Dual Page 8 of 26 Model 4069E ExtrudeIR Instruction Manual Operating Instructions WIRING CONNECTIONS Research Inc Installation This section describes how to wire the Model 4069E power control system The features and options mentioned here are identified in the model number found inside the enclosure WARNING Hazardous voltages are present at the main disconnect switch and load terminals Always remove AC line voltage from the system before making contact with internal assemblies line or load wiring or fuses Also remove AC line voltage from the system before making connections equipment changes or resistance measu2. INDICATORS Main Disconnect Switch System ON OFF Switch Indicator Light Watlow F4 Process Controller Research Inc Operating Instructions Figures 4 amp 5 shows the location of the controls and indicators The main disconnect switch turn on and off the power control system Note the following Before turning on the disconnect switch check the following 1 The load is wired and ready for power to be applied to it 2 All safety precautions are observed The System ON OFF switch allows the operator to enable or disable the power going to the load This is accomplished by removing power from the AC contactor This in turn removes power from the SCR controller Additionally this will enable or disable the water and air solenoids chamber fan and control console indicator light e Indicator light off indicates all systems controlled by ON OFF switch are disabled e Indicator light on steady indicates power is applied to the heater power controller and chamber fan air and water solenoids are enabled e Indicator light flashing slowly three seconds on one second off indicates either the Remote Interlock is open or the Motion Detection Sensor has stopped e Indicator light flashing fast one second on one second off indicates that the chamber cooling flow switched and or thermostat has tripped The Watlow F4 Process Controller is used to increase voltage to the lamps display settings and display alarm messages
3. Reinsert the edges of the liner into the grooves of the quartz liner bracket Reinstall the other bracket and secure with the two bracket screws Repeat this process for the other half of the liner Clean reflectors provide the greatest radiant efficiency If the reflector surface becomes contaminated it reflects less energy The energy that is not reflected is lost absorbed by the reflectors and removed by the cooling water and air The following procedure should be used to clean the Model 4069 reflectors 1 Remove the lamps and quartz liner as described in Lamp Removal Replacement Installation and Split Quartz Liner Cleaning and Replacement Clean the reflectors 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 and quartz liner as outlined in Lamp Removal Replacement Installation and Section Split Quartz Liner Cleaning and Replacement If necessary the reflectors may require re polishing This is permissible because the reflector is solid aluminum and can be re polished many times without dam
4. e The Watlow F4 Process Controller is shipped in manual mode e The upper display reads output percentage directly e The lower display provides alarm message identification e Change voltage output to lamps as follows 1 Use the scroll up down buttons to move the cursor to Manual Pwr 2 Push scroll right to select Manual Pwr 3 Use the up down scroll buttons to increase or decrease output value percentage 4 Push scroll right button to enter new output value which is applied immediately Page 13 of 26 Model 4069E ExtrudeIR Instruction Manual Operating Instructions Actuator Control The black white buttons on the control console control movement of the actuators that provide elevation adjustments to the chamber e The left black white controls the left actuator e The right black white controls the right actuator E stop Fast Stop Activation of the E stop will disable the chamber contactor which cuts power to the lamps cooling fan and water and air solenoids To reset the E stop switch turn the switch head to the right Figure 4 Main Disconnect Research Inc Page 14 of 26 Model 4069E ExtrudeIR Instruction Manual Operating Instructions Research Inc Figure 5 Actuator Control Left Watlow Controller Actuator Control Right On Off Switch Extrude IR INFRARED HEATERS f Gmo Indicator E stop Light Page 15 of 26 Model 4069E ExtrudeIR Instruction Manual Dimensions
5. 4069 LINER CLEANING for periodic cleaning Use the following procedure to AND remove reinstall clean the quartz liner REPLACEMENT Research Inc Page 17 of 26 Model 4069E ExtrudeIR Instruction Manual Dimensions and Specifications Research Inc Note Remove all power from the heater BEFORE attempting to install replace the lamps Always use clean cotton or latex gloves when handling the split quartz liner so as not to deposit any oils or grease from your hands onto the surface of the split quartz liner 1 Open the Model 4069 Heater to allow access to each heater half for split quartz liner installation 2 Loosen the screws of one liner bracket and slide the bracket away from the quartz liner of one liner half at one end of the heater while supporting the liner with other hand Figure 7 Figure 8 3 Remove the bracket from the end casting of the heater 4 Gently slide the quartz liner out of the grooves of the liner bracket from the opposite end Take care so that the quartz liner does chip or crack as it is removed Page 18 of 26 Model 4069E ExtrudeIR Instruction Manual Dimensions and Specifications CLEANING THE REFLECTORS Research Inc Figure 9 FUO If cleaning the liner use a non abrasive glass cleaner i e household ammonia and water or isopropyl alcohol and a clean dry lint free cloth After cleaning do not touch the outside surface of the liner unless wearing cotton gloves
6. and Specifications ROUTINE MAINTENANCE LAMP REMOVAL REPLACEMENT INSTALLATION Research Inc Maintenance and Trouble Shooting The following bi monthly routine maintenance is suggested 1 Remove power connection to the system Lock out power if possible Carefully vacuum any dust or dirt collecting within the enclosure Use caution to not disturb the wiring Service more often in dust locations 2 Clean the outside of the enclosure with glass cleaner and a soft cotton cloth as necessary The T3 style lamps are installed into the Model 4069 when shipped from the factory The following procedure details the process to replace the lamps in the Model 4069 reference Figure 6 7 amp 8 Note Remove all power from the heater BEFORE attempting to install replace the lamps Allow a minimum of 12 inch 12 mm of slack in the lamp leads so that the leads are not taut when inserted into the lamp terminal blocks 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 envelopes 1 Remove quartz liner see next section Take this opportunity to clean the liner Remove end cover screws 4 per end cover Remove end covers on both ends of the heater Remove end reflector screws 2 per reflector Remove end reflectors on both ends Carefully disengage lamp from clips both ends Slide the end of the lamp through the rectangular cutout
7. pin or lamps Setpoint switch 16 is positive and 17 is negative is in REMOTE Opera 2 Units with Temperature control option Place tion O K with Setpoint temperature controller in manual mode with 50 switch in LOCAL if not percent output Verify 2 5VDC at TB 100 pins 16 see above and 17 Refer to the temperature controller manual regarding repairs Full voltage cannot be 1 Verify the load lamps or heaters are not drawing obtained current at full capacity of the system Rotate the current limit pot on the power controller 1 turn counterclockwise If the load current decreases the current limit is controlling the output 2 Verify the line voltage Load voltage maximum is approximately 98 percent of the line voltage 3 Test in LOCAL setpoint mode Set the Local Setpoint potentiometer to 900 The voltage should be 216 240 volt line or 432 480 volt line Adjust the RUN SPAN potentiometer of the power controller as necessary 4 Faulty power controller SCR or control circuit Refer to the power controller manual regarding repairs Load voltage will not go 1 Verify the load voltage will go to zero with the SCR to zero switch set to DISABLED If it does not refer to the power controller manual regarding repairs 2 If the shorted SCR indicator of the power controller is on an SCR has failed 3 Units with the Product Detect option Normal operation of the idle circuit The idle potentiometer maintain
8. 0 005 19kW or 29kW maximum power rated heater 16 inch length 1600 watts 103390 012 56KW maximum power rated heater 16 inch length 3600 watts 103390 007 30kW or 45kW maximum power rated heater 25 inch length 2500 watts 103390 010 46kW or 68kW maximum power rated heater 38 inch length 3800 watts Replacement Reflector For 106721 001 10 inch length 106721 002 16 inch length 106721 003 25 inch length 106721 004 38 inch length Replacement End Reflectors Four required per heater for 106778 001 12 reflector size heater 106778 002 18 reflector size heater Spare Split Quartz Liner Half Two required per heater for 106895 001 12 reflector 10 inch length 106895 002 12 reflector 16 inch length 106895 003 12 reflector 25 inch length 106895 004 12 reflector 38 inch length 106895 005 18 reflector 10 inch length 106895 006 18 reflector 16 inch length 106895 007 18 reflector 25 inch length 106895 008 18 reflector 38 inch length M4069C Additional Operation Manual Research Inc Page 26 of 26
9. BLE Figure 1 Research Inc Page 10 of 26 Model 4069E ExtrudeIR Instruction Manual Operating Instructions Power Wiring Connections Line Connections Referring to the wiring specification in Table 3 1 connect the external power lines to the top of the disconnect switch Load Connections The model 4069E control system has 2 3 pole load fuseblocks for distributing the Three phase power to your process For the 120 Amp systems do not exceed more than 60 amps 3 phase per fuseblock For the 160 Amp systems do not exceed more than 80 amps 3 phase per fuseblock The heater load should be wired to evenly distribute the number of individual lamps or heating elements to the 2 three phase load circuits It is suggested to balance the load circuits by having the same number and size of lamps or heating elements per phase and per load circuit ELECTRICAL REPRESENTAT TO F TO F TTOM HALF HEATER ER HALF HEATER TO F _ Figure 2 Research Inc Page 11 of 26 Model 4069E ExtrudeIR Instruction Manual Operating Instructions CONTROL CONNECTIONS Remote Interlock This feature provides for remote process interlock shutdown of the heater power This is accomplished by opening the heater power controller contactor With the interlock Switch open the heater cannot be turned on from the control system front panel The switch contacts must be open during the heat
10. Model 4069E User s Manual Chamblti PAGA Ac H ea tens Publication 107606 001 Rev 1 Feb 2009 Another quality product from RESEARCH INC PROVIDING CONTROLLED ENERGY DRYING 4 CURING A HEATING 7128 Shady Oak Road Eden Prairie MN 55344 Phone 952 949 9009 Fax 952 949 9559 E mail info researchinc com www researchinc com Dear Valued Customer Thank you for purchasing a Model 4069E ExtrudeIR 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 4069E curing system 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 4069E Requirement Additional information regarding application of the Model 4069E 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 Terry Nigon President Research Inc Model 4069E ExtrudeIR USE
11. R Manual Contents Section page INTRODUCTION General Description s cuna de le nests he te co ate as ee cd aL ae e teen 1 Standard Features 1 o acess Aa nGg ate atan nah SAYA NG YS PYRA G DA donee eee 2 O A AN 3 SPECIFICATIONS Specifications RA 4 Dimensions TG TOTO CHA CA KC cc 5 INSTALLATION Waning COnMeECHONS an loe ade ta fa ATA de Baha elec ka ets el Ah AG Yn Palang Ta 10 PS Ratno A A SO RAN 10 NI A AO A Ny ote AN Ro Ty cea 10 Electrical aunts o aa a ae ta dd aa dea NG AA do o 10 POWER Vina COME CONS ei a recaen 10 Control Connections ss s i i i lt i lt i lt i lt i lt i isSsSstsSss 12 Remote Interlock Switch ee 12 Remote o Ta ote ele A GO a uals A opis 12 Water Connections ss L 12 Air Connections eee 12 OPERATING INSTRUCTIONS Controls and Indicators n a A A A elegy ete 10 Main DISCOS corto cc letal edad ido dad Se 10 System OM SIE rt bo et nd nha na cela e ec a 10 Indicator Light RCCC C O 10 Watlow F4 Process Controller eee 10 Actuator Canta 12 E A AR NA RIA 12 MAINTENANCE AND TROUBLE SHOOTING Routine Maintenance 16 Lamp Removal Replacement and Installation kO 16 Split Quartz Cleaning and Replacement aL 17 Cleaning the Reflectors 19 Model 4069E ExtrudeIR USER Manual Contents DIMENSIONS AND SPECIFICATIONS Controls 20 Heater 22 Model 4069E ExtrudeIR Instruction Manual Introduction General Description Standard Features Research Inc Introduction The Model 4069E Ext
12. age from continued erosion A fine particle polishing compound such as a chrome semi chrome or soft metal polishing compound may be used These types of compounds can be found at a local automotive or metal polishing supply house Follow the polishing instructions listed on the polishing product Page 19 of 26 Model 4069E ExtrudeIR Instruction Manual Dimensions and Specifications The reflectors can be removed from the Model 4069 Heater to make cleaning and maintenance easier The following procedure should be used to remove the Model 4069 reflectors Note Remove all power from the heater BEFORE attempting to install replace the heater reflectors 1 Drain all cooling fluid from the heater and blow out the heater cooling lines with compressed air 2 Remove the heater cover screws and heater cover Figure 10 3 Disconnect the cooling line from the reflector to be maintained 4 Loosen all screw from all reflectors on one side of the end casting of the reflector to be maintained 5 Remove the reflector mounting screws from the end casting of the reflector to be maintained 6 Remove the reflector Research Inc Page 20 of 26 Model 4069E ExtrudeIR Instruction Manual Dimensions and Specifications Figure 11 Research Inc Page 21 of 26 Model 4069E ExtrudeIR Instruction Manual Dimensions and Specifications TROUBLE Heater Contactor will not Ver
13. e extrusion Flash cure coatings between operations Heater Module A circular array of individual parabolic polished aluminum reflectors direct the infrared energy generated by the quartz lamps towards the center axis of the heater Each heater houses either 12 or 18 reflectors depending on the model The 12 reflector model accepts product sizes up to 2 inches in diameter while the 18 reflector model accepts products up to 4 inches in diameter Heated lengths of 10 16 25 and 38 inches 254 406 635 and 965 mm are offered for the Model 4069E For applications prone to product sagging a dual heater system with two 10 heated length chambers and a intermediate product support between them is available The chamber s clam shell design offers easy access for liner cleaning and lamp servicing by simply releasing the latches on the front of the chamber and lifting the upper half Gas springs are provided to assist with the left gas spring having a integral extension lock The factory installed ceramic end seal T3 style lamps provide precise levels of power to the product in the chamber The lamps generate infrared energy at a peak wavelength of 1 2 microns at rated voltage This wavelength is commonly known as short wavelength or NIR Near Infrared The lamps reach 90 of full operating temperature within three seconds of a cold start Radiant energy is dissipated to 10 five seconds after power is shut down Additional lamps can be ordered separatel
14. elescopic 8 lift 24 V Cart 106783 011 Replacement Gas Spring for 4069 12R 10L 106783 012 Replacement Gas Spring for 4069 12R 16L 106783 013 Replacement Gas Spring for 4069 12R 25L 106783 014 Replacement Gas Spring for 4069 12R 38L 106784 011 Replacement Gas Spring for 4069 18R 10L 106784 012 Replacement Gas Spring for 4069 18R 16L 106784 013 Replacement Gas Spring for 4069 18R 25L 106784 014 Replacement Gas Spring for 4069 18R 38L 106783 013 Replacement Gas Spring for 4069 12 DUAL 106784 013 Replacement Gas Spring for 4069 18 DUAL Gas Spring with Latch Replacement 107358 011 Replacement Gas Spring amp Latch for 4069 12R 10L 107358 012 Replacement Gas Spring amp Latch for 4069 12R 16L 107358 014 Replacement Gas Spring amp Latch for 4069 12R 25L 107358 014 Replacement Gas Spring amp Latch for 4069 12R 38L 107396 011 Replacement Gas Spring amp Latch for 4069 18R 10L 107396 012 Replacement Gas Spring amp Latch for 4069 18R 16L 107396 013 Replacement Gas Spring amp Latch for 4069 18R 25L 107396 014 Replacement Gas Spring amp Latch for 4069 18R 38L Research Inc Page 25 of 26 Model 4069E ExtrudeIR Instruction Manual Dimensions and Specifications Accessories Spare and Replacement Parts Heater Model Description Replacement Lamp For 103390 003 12kW or 18kW maximum power rated heater 10 inch length 1000 watts 103390 004 24kW or 36kW maximum power rated heater 10 inch length 2000 watts 10339
15. er off condition If this feature is desired connect using the following procedure 1 Remove the factory installed jumper at TB 1 pins 17 and 18 2 Connect the normally open contacts of the switch to TB 1 pins 17 and 18 If more than 1 interlock switch is used in a system wire the contacts in series and then connect to the system This feature provides for remote process fast stop shutdown of the heater power water Remote Fast Stop and fan cooling This is accomplished by opening the heater power controller contactor With the fast stop open switch the heater cannot be turned on from the control system front panel The switch contacts must be open during the heater off condition If this feature is desired connect using the following procedure 3 Remove the factory installed jumper at TB 1 pins 19 and 20 4 Connect the normally open contacts of the switch to TB 1 pins 19 and 20 If more than remote fast stop switch is used in a system wire the contacts in series and then connect to the system Water Connections Use male 3 8 NPT fittings to connect the water input and output ports See Specifications for required flow rates Air Connections Use a male 3 8 NPT fitting for the air input connection when the optional Air Curing Nozzles and or Pyrometer have been ordered WATER IN MwWATER OUT Figure 3 Research Inc Page 12 of 26 Model 4069E ExtrudeIR Instruction Manual Operating Instructions CONTROLS AND
16. ify line voltage is applied to the main disconnect SHOOTING energize switch Rh 2 Verify remote heater open remote process interlocks or water flow switches if used are closed 3 If not using remote heater enable heater open interlocks or water flow switches verify the 2 pin jumpers are installed between TB 100 pins 2 to 3 10 to 11 and 14 to 15 4 Check fuses FU 1050 FU 1051 FU 107 FU 108 and TB 100 pin 1 Verify the Heater On indicator is illuminated Rh No output to load heaters or lamps Setpoint switch a Verify a 0 5 VDC signal is present on pins 13 and 14 is in LOCAL mode of the power controller connector This voltage is proportional to the setting of the local Setpoint potentiometer or the idle potentiometer product detect option if product is not detected 3 If the over current light on the controller is illuminated check the load wiring lamp or heater connections for short circuits 4 If the shorted SCR light is lit on the controller refer to the power controller manual regarding repairs 5 If the COMMAND led on the power controller is not lit and a control signal is greater than 10 percent is applied refer to the power controller manual regarding repairs Research Inc Page 22 of 26 Model 4069E ExtrudeIR Instruction Manual Dimensions and Specifications Symptom Action No output to load heaters 1 Verify the polarity of the remote input TB 100
17. in the end casting on one end of the heater through the rectangular cutout in the end casting of the other end of the heater ALDEA 8 Position the lamp over the lamp clips so that the lighted portion of the lamp is equally space in the reflector Note Be sure that the Gas Fill Tip is facing away from the reflector 9 While holding the lamp on both ends by the ceramic end seals with light pressure push the lamp into the lamp clips A slight twisting motion of the lamp while pushing the lamp into the clip helps the lamp to seat properly Page 16 of 26 Model 4069E ExtrudeIR Instruction Manual Dimensions and Specifications 10 11 Figure 6 Cut wire to a length allowing for a service loop Strip back the insulation on the end of the lamp leads approximately 1 1 2 inches 38 mm 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 1 0 Ft Lbs 1 4 N m Form a loop within each lead along its length This loop will act as a strain relief within the lead during normal operation of the heater Reinstall the end reflectors end covers and quartz liner SPLIT QUARTZ The split quartz liner can be replaced or removed from the Model
18. kg 10 QIH240 103390 501 4069E 12R 10L 12kW 480V 554 1000 1000RI2 Eaz 12 0 1 2 4 5 227 16 QUH240 103390 515 4069E 12R 16L 19kW 480V o6 1600 1600R2 10322 240 19 2 1 8 6 9 034 a 3800 SI Pa 480 68 4 da jee 37 1000 ES pigs 240 36 3 4 13 30 Recommended maximum product diameter for 12 reflector models is two inches Recommended maximum product diameter for 18 reflector models is four inches Stated flow rates are for each of two flow paths xxx Maximum inlet water temperature not to exceed 100 F 37 C 9 1 Research Inc Page 5 of 26 Model 4069E ExtrudeIR Instruction Manual Introduction Research Inc Page 6 of 26 odel 4069E ExtrudeIR Instruction nual Operating Instructio DIMENSIONS pa 32 63 m DDIA 1 li 0 a B A il o Gu Bil bi P Panie a o i ALO y M L e 44 00 MODEL NUMBER A B C DOA MIN MAX MIN MAX 4089P 12R10 wo eran aaas wa 4089P 12R19 Es ean gg wa mos aa GE 089P 12R3AL din ayan Gaga va 4069P 18R 10L Ge ediy daouig dn om 4069P 18R46L cal eaa daaag po 089P 18R29 gen jag daaag po 4009 18 28 dial eae dadas ds corno 29 Epee agag 7 COPIER AOLDUAL e mb ao na
19. n to the pyrometer Page 2 of 26 Model 4069E ExtrudeIR Instruction Manual Introduction Booster Pump An optional booster pump is available when plant water pressure is too low to provide adequate flow rate for proper cooling of the chamber Pump will raise the water pressure up to 50 PSI General Gas Shock High Temperatures Research Inc Electrical Safety The Model 4069E 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 and 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 A latching shock is installed on the left side of the model 4069 heater The latch will prevent the heater from closing should the gas strut fail When closi
20. ng the heater pull the knob to release the latch while closing Failure to release latch can cause damage to the heater if forced closed 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 There is danger of electrical shock when servicing the heater Page 3 of 26 Model 4069E ExtrudeIR Instruction Manual Introduction 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 ALWAYS disconnect the power lines AND any optional interlock circuits before installing or changing lamps NEVER operate the heater with end covers removed Research Inc Page 4 of 26 Model 4069E ExtrudeIR Instruction Manual Introduction Specification Model Number Lamp Lighted Length Inches mm Lamp Wattage Lamp Type Lamp Part Number Lamp Rated Voltage Wattage Heater kW Water Flow GPM LPM Pressure Drop Through Heater Required Water Flow psi 5psi Total Weight Pounds
21. r level to the lamps On Off switch indicator light actuator adjust switches and a fast stop Power Control Cabinet A NEMA 12 cabinet containing components to accurately control power to the system Product Motion Detection An optional low torque roller providing rotational feedback can be positioned at either end of the chamber to signal product stoppage If no signal is detected the system immediately will shut down power to the chamber thus reducing the incidence of the product burning in the chamber When motion is restored the lamp voltage will be re applied to a the preset value Air Curing Nozzles Optional twin air curing nozzles can be attached to the input end of the heater These nozzles force air down the length of the quartz liner and provide a convective component to the curing process This option includes a fitting for house air a filter and regulator in addition to the nozzles Exhaust Hood An optional exhaust hood attaches to the exit end of the single chamber system or between chambers on a dual chamber system to collect smoke and gasses given off during heating the process 3 inch diameter is used all 12R units and a 4 diameter is used on all 18R units Pyrometer The optional pyrometer is useful for monitoring product temperature in sensitive areas The mounting bracket provides multiple sensing positions for full product coverage This option includes a fitting for house air a filter and regulator in additio
22. rements Conduit entry into the system should be made near the right side of the cabinet for power wiring Assure that metal fragments are not allowed to fall into the equipment while holes are made for conduit fittings See Figure 1 Wire Ratings Wire Temperature Rating 75 C or Higher Line Load Wiring Voltage Rating 240 VAC systems 300 VAC Minimum Line Load Wiring Voltage Rating 480 VAC systems 600 VAC Minimum Allowable Wire Sizes Current Line Load Ground Control Rating of Connections Connections Connection Circuit System Connections 120 Amp 6 250 MCM 6 250 MCM 4 1 0 AWG 22 10 AWG 160 Amp 6 250 MCM 6 250 MCM 4 1 0 AWG 22 10 AWG Recommended Minimum Wire Sizes NOTE Wire temperature and connector ampacity ratings are based on NEC 310 16 using 73 C copper wire de rated for 50 C ambient environment Current Line Load Ground Control Rating of Connections Connections Connection Circuit System Connections 120 Amp 1 AWG 6 AWG 6 AWG 16 AWG 160 Amp 2 0 AWG 4 AWG 6 AWG 16 AWG Electrical Inputs Heater open interlock switch Contacts Rated for 120 VAC at 2 0 A Cooling flow interlock switch Contacts rated for 120 VAC at 100 mA Heater over temp thermoswitch Contacts rated for 120 VAC at 100 mA Remote interlock switch Contacts rated for 120 VAC at 100 mA Page 9 of 26 Model 4069E ExtrudeIR Instruction Manual Operating Instructions CONNECT POWER THIS SIDE IF POSSI
23. rudeIR curing System uses high intensity infrared lamps and polished aluminum reflectors to deliver heat precisely where it is needed for many curing and drying applications on extrusion lines It can be used effectively to provide a surface cure to rubber extrusions dry adhesives and coatings on rubber or metal and provide in process curing between layers of multi layer cable Depending on the model selected diameters as small as 44 inch or a large as 4 inches can be processed This system includes along with the Model 4069 ChamberIR heater an operator interface pedestal with a Watlow PID controller a split quartz liner height adjustment with plus minus 15 degrees of tilt off horizontal and convenient connection points for power water and air Optional features that can be ordered with the unit include an optical pyrometer to monitor product temperature product break sensing to shut power down if the line brakes and an air nozzle kit to provide forced air inside the heating chamber to increase efficiencies in curing and drying The single chamber models are an efficient solution for most applications and the dual chamber models provide additional product support to allow fragile product to run through the system without breaking or drooping Typical applications for the Model 4069E include Surface cure on rubber extrusion Drying adhesives and coatings on rubber or metal Soften and Cure between multi layer extrusions Cast and hold the shap
24. s the voltage at idle 4 Units with the Conveyor Web speed option Normal operation The minimum idle potentiometer may be adjusted to lower the load voltage to zero if the web is stopped Research Inc Page 23 of 26 Model 4069E ExtrudeIR Instruction Manual Dimensions and Specifications Research Inc Page 24 of 26 Model 4069E ExtrudeIR Instruction Manual Dimensions and Specifications Accessories Spare and Replacement Parts Controls Model Description Control Cabinet 096191 006 Contactor 3 phase 100 amp 24 VDC coil 107556 009 Fuse Cubefuse 100 amp 086445 016 Fuse Time Delay CC 6 amp 600 VAC 090744 020 Fuse Current Lim CC 1 6 amp 099395 001 Switch On Off 3 phase 100 amp 099396 001 Switch Actuator Red Yellow 107549 001 Power Supply 480 VAC in 24VDC out 099556 003 PLC 115 240 8 DC in 6 relay out 099556 010 Output Module PLC DIO5 06 4 PT 080821 001 Relay DPDT 10 amp 24VDC 650 ohm 055899 015 Relay SS DC 125 amp 480 VAC 107321 001 Transformer 250 VA 480 240 to 240 120 066798 004 Varistor Assembled 480 VAC 055300 289 Resistor MF 1 4W 1 10K ohm Control Console 107525 001 Watlow F4P Series process controller 107392 004 Switch Push Button 2 head 107392 001 Switch Push Button E stop 107391 003 Switch Rotary 3 position 107390 002 Contact Block Normally open 107390 001 Contact Block Normally closed 107393 003 Indicator Light Amber 24 120 VAC DC 107439 001 Actuator T
25. y from the heater Page 1 of 26 Model 4069E ExtrudeIR Instruction Manual Introduction Standard Features Optional Features Research Inc Heater Positioning The chamber is mounted to actuators at each end allowing for variations on product elevation Each actuator can operate independently allowing for up to 15 off chamber tilt This can be useful when product sagging is occurring Water Cooling Each reflector is designed with an internal coolant passageway to allow coolant to flow through its entire length during operation Water lines run from the fittings on the base of the cart to the heater Adequate cooling water is required during operation of the Model 4069E Required cooling water flow rates are listed in Specifications Air Cooling A cooling fan is designed into the Model 4069 housing and provides ambient airflow through the heater body This airflow helps to prevent air borne contamination from depositing on the reflector surfaces It also provides cooling to the quartz halogen lamp end seals Split Quartz Liner A split quartz liner is included with the Model 4069 and provides contamination protection for the aluminum reflectors When installed in the heater the quartz liner protects the aluminum reflector and lamp from contaminants released in the heating process resulting in maximum efficiency of the heater Operator Interface The operator interface includes a Watlow PID controller for setting the powe
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