Model 5209 User Manual - Precision Control Systems, Inc.
Contents
1. Item Part Number Part Description 1 054979 020 SCREW PH 4 40 3 8 SST 2 054979 042 SCREW PH 6 32 1 4 SST 3 054979 052 SCREW PH 6 32X5 8 SST 4 054979 105 SCREW PH 10 32X1 4 SST PH 5 054982 001 NUT KEP 4 40 NC ZINC 6 055020 087 SCREW FH 10 32X1 2 SST 100 7 055296 037 SCREW SOCKET 10 32 X 1 1 2 SS 8 055298 013 SCREW SET2 56X1 4 ALNCUP SST 9 070025 015 THERMOSTAT SURF NC 160F 10 106514 013 Harness W Receptical Model 5209 05 108 106514 011 Wire Harness W Receptical Model 5209 10 10 106514 012 Harness W Receptical Model 5209 16 11 100571 001 TERMINAL BLOCK CERAMIC 2P 10A 12 103390 004 LAMP QIH240 2000 V CER END 12 103390 002 LAMP 240V 1000W 5 inch 127 mm Lighted Length 12 103390 004 LAMP 240V 2000W 10 inch 254 mm Lighted Length 126 103390 006 LAMP 384V 3200W 16 inch 406 mm Lighted Length 13 103830 001 FITTING POLY 1 8NPT INSTANT 14 104358 001 FITTING ELBOW 3 8NPT 15 104358 002 FITTING POLY 1 8NPT 2500D TUBE 90 ELBOW 16 104399 001 FITTING POLY 3 8NPT 1 2TUBE INSTAN 17 105083 001 COUPLING TUBING 1 2 18 106176 001 FITTING PLUG 1 2 TUBE 194 106502 001 COVER 5209 10 195 106502 002 COVER 5209 16 19c 106502 003 COVER 5209 05 20 106503 001 END COVER 5209 XX 21 106504 001 BRKT LAMP POS 5209 XX 22 106505 002 MANIFOLD 5209 XX 22. LAM LAMP LAM LAM 19 m 12 LAMP LAM MATING FACE 16 THERMOSTAT 17 GROUND GRNFTLW Figure 4 2 Each heater is supplied with either a 10 or 20 ft 3 or 6 m removable electrical cable that mates directly to the pinned connector mounted to the heater cover see Figure 4 3 The cable length is specified within the heater model number at time of order Each wire housed within the cable assembly extends approximately 2 ft 0 6 m beyond the end of the cable conduit This extra wire length allows the cable to be installed within the optional electrical junction box or within an appropriately designed power source An optional electrical junction box is available and can be ordered along with the Model 5209 heater The physical dimensions of this junction box are shown in Specifications Section 6 MATING FACE GRASILW GRH YLW Figure 4 3 As shown in Figure 4 4 the junction box is designed to accept wiring from the removable heater cable as well as wiring from the electrical power source Different wiring configurations are shown so that the heater wiring can be correctly connected within the junction box corresponding to a particular supply line voltage i e since the Model 5209 05 5209 10 and 5209 16 mod
3. the setscrews in the ceramic While holding the lamp gently pull the lead wires out of the Both lead wires of the lamp need to be trimmed prior to While holding the replacement lamp by the ceramic end Form a loop within each lead along its length from the top terminal blocks on each end of the heater corresponding to the lead wires of the lamp to be replaced ceramic terminal blocks and set the old lamp aside for disposal installation into the heater Figure 5 3 details the proper lengths to which the lead should be trimmed and stripped seals place the lamp into the groove machined into each lamp bracket plate 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 Lamp Enyel pe previously held the old lamp Push each lead wire into the terminal block far enough so that when Lamp Endseal tightened the setscrew will hold the lead securely A Lamp Lead Wire Tighten the setscrews in each terminal block so the lead wires held securely Note tighten the 0 25 in Strip Length terminal block set screws to a torque of 0 6 feet 4 00 in Overall Wire Length Ibs 0 82 N m igure 5 groove machined into each of the aluminum cooling manifolds located
4. 240V 384V 3 PHASE LI TSTAT 16 17 O O O 5 Maintenance amp Troubleshooting The repair and maintenance of the Model 5209 includes replacement of the T3 style lamps and quartz wind and cleaning of the reflector Lamp Removal Replacement Installation The six T3 style lamps are installed into the Model 5209 heater when shipped from the factory The following procedure details the process to replace the lamps in the Model 5209 reference Figure 5 1 5 2 amp 5 3 Note Remove End Cover Screws 3 per end cover Remove End Covers on both ends of the heater Remove all power from the heater BEFORE attempting to install replace the lamps Allow a minimum of V amp inch 12 mm of slack in the lamp lead so that the lead is not taut when inserted into the lamp terminal block 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 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 Take this opportunity to clean the window using non abrasive cleaning solvent and clean soft cotton cloth see Section 6 10 Arrange the lead wire on each end of the lamp into the 11 12 Reinstall the quartz window within the heater by carefully 13 Reinstall both end covers and secure each to the heater Loosen do not remove
5. Control System with Pyrometer Input Power Control System with Thermocouple Input PC VM Control System with Digital Volt Meter 1 Model 5209 heater supplied with Model 915 ControllR Power Control Systems Must specify electrical cable length either 10 or 20 feet 3 or 6m when ordering any of the PC Option choices Lighted Electrical Cable Optional Length Length Equipment Typical Model 5209 16 10 W PC TCT Number 17 Accessories Spare amp Replacement Parts Model 5209 Model 106580 003 106580 001 106580 002 103390 002 103390 004 103390 006 106513 001 106514 001 106514 002 10661 7 001 106618 001 Description Quartz Window 5 inch 127 mm lighted length heater Quartz Window 10 inch 254 mm lighted length heater Quartz Window 16 inch 406 mm lighted length heater Quartz Halogen Infrared Lamp Ceramic end seal 5 inch 127 mm lighted length Quartz Halogen Infrared Lamp Ceramic end seal 10 inch 254 mm lighted length Quartz Halogen Infrared Lamp Ceramic end seal 16 inch 406 mm lighted length Electrical Junction Box accepts Model 5209 Removable Electrical Cable 10 ft 3 m Electrical Cable Assembly 20 ft 6 m Electrical Cable Assembly Cooling Air Regulation Kit Cooling Water Plumbing Hardware Kit 7 Spare amp Replacement Parts Replacement parts for the Model 5209 are listed below Reference Figure 7 1 when using this list
6. 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 or radiant heat chamber 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 reflectors or metal parts near the lamps may cause severe burns In addition extremely hot exhaust air is generated during operation of the Model 5209 Figure 2 1 depicts areas on the heater from which the exhaust air will leave the heater aa 2 N 2 Figure 2 1 IWARNING NEVER place hands under or in front of the heating elements ALWAYS allow heating element to cool at least three minutes before touching the lam
7. 3 106506 001 FITTING PLUG 1 4NPT BRASS 24 106508 001 REFLECTOR 5209 10 in 24g 106508 002 REFLECTOR 5209 16 in 24c 106508 003 REFLECTOR 5209 5 in 25 103843 001 TUBING POL Y FLO 1 4 ODX0 04 WT 26 104431 001 TUBING 1 2 DIA X 2 5L 27 10651 1 001 BUSHING SNAP 50 ID 75 DIA PNL 28 106518 001 FITTING RED 3 8FPT 1 8FPT BRS 29 106519 001 FITTING NIPPLE 1 8X1 8 3 4L BRS 30 106580 001 WINDOW QUARTZ 5209 10 in OPTIONAL 30g 106580 002 WINDOW QUARTZ 5209 16 in OPTIONAL 30 106580 003 WINDOW QUARTZ 5209 5 in OPTIONAL 19 nig 2S RR NAP N Ware Figure 7 1
8. 5209 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 cover and are designed for mounting the heater see Figure 3 1 Note Vertical burn lamps are recommended when operating the Model 5209 in a vertical orientation All PCS Research Inc lamps associated with the Model 5209 heater are designed for vertical operation 10 32 THDS MOUNTING LOCATIONS 4 TOP VIEW 0 50 IN TUBE 2 1 12 WATER PORT 2 FRONT VIEW END VIEW Figure 3 1 Model Number Dimensions Inches mm A B C 5209 05 1 8 45 7 5 5 139 7 9 10 231 1 5209 10 3 73 94 7 7 00 177 8 14 45 367 0 5209 16 3 73 94 7 12 63 320 8 20 08 510 0 Figure 3 1 Model 5209 mounting hole and heater cooling connection locations 6 IN CONTROL CABINET SIDE VIEW 3208 HEATER ANT FLOW RESULATOR 8 20 RETURN 3 8 Figure 3 2 4 Operating Instructions Heater Cooling Connections Each Model 5209 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 f
9. Instruction Manual INFRARED HEATERS Heater Model 5209 November 2008 Another quality product from PROVIDING CONTROLLED ENERGY DRYING 4 CURING 4 HEATING 7128 Shady Oak Road e Eden Prairie MN 55344 952 949 9009 Fax 952 949 9559 www researchinc com sales researchinc com Contents 1 6 7 Pun m m ety 1 T tr d ctioi sro enee dete dtu bout estan ee 1 General Description 1 Heater Mod le ne 1 COO LMG 1 Air OLN si cide Sl ee 1 Removable Electrical Cable oue en REESE Rd qud 1 Heater i D Re 2 Optional Quartz Window eh tv Ule teh ag ec o cabo Sess tbe Ul Ten 2 Optional Electrical Junction BOX zu usa ar ee 2 Optional Power Control System unse 2 Standard Feat res Ee EEE aes 3 Rapid Responses EE 3 LONLNUOUS OpEralan rs ara ERBE 3 Controllable Energy 3 E A 4 E INA E 4 Hist Temperatures ope m ena NR Be 4 Electrical Safety se due nein 5 Fire geniessen 5 ee 6 Unpack Check for Damage ke
10. at either end of the heater Each groove corresponds to each of the individual lamps of the heater 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 sliding the window into the grooves machined into the heater reflector with the three screws per end cover Note tighten the end cover screws to a torque of 1 7 ft lbs 2 3 Figure 5 4 13 Quartz Window Cleaning and Replacement The optional quartz window can be replaced or removed from the Model 5209 for periodic cleaning Use the following procedure to remove reinstall clean the quartz window 1 2 5 6 Remove the three 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 non abrasive glass cleaner and a clean dry lint free cloth After cleaning do not touch the inside surface of the window unless wearing 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 the end cover mounted to the heater Reinstall the other end cover and secure with the three end cover screws Cleaning the Reflector A clean reflect
11. e tubing and plumbing fittings are supplied with each heater for easy installation Required cooling water flow rates are listed in Specifications Section 6 Air Cooling Compressed air cooling must also be supplied to the heater for proper operation This cooling air removes excess heat from around the lamp end seals Flexible tubing and matching plumbing hardware is included with each heater Required airflow rates and pressures are listed in Specifications Section 6 Removable Electrical Cable The Model 5209 heater is electrically wired from the T3 lamps to intermediate terminal blocks within the heater Further wiring from each terminal block to a pinned connector on the top of the heater is also included A 10 ft 3 m removable electrical cable is supplied with each heater that is designed to mate with the heater s pinned connector This cable is designed for installation within an electrical junction box optional item or installed within an appropriately designed power source Heater Safety An integrated thermostat is mounted to the backside of the aluminum reflector The thermostat is wired to the pinned connector with corresponding wiring residing in the removable electrical cable When wired into an appropriately designed power source the normally closed thermostat will open upon reaching an overheat condition preventing electrical power from reaching the heater The thermostat will close once the heater cools down to a safe opera
12. els use T3 lamps rated for 240 volt operation one could install the heater wiring so that either 240 volt single or three phase supply power could be used Heater Thermostat As stated above a heater safety thermostat is mounted to the back of the model 5209 reflector and wired into the 19 pin connector mounted to the heater cover Wiring for the thermostat is also integrated within the removable electrical heater cable When wired into an appropriately designed power source i e the Model 915 ControllR Power Control System See Appendix for detail the normally closed thermostat will open upon reaching an overheat condition 160 F resulting in an alarm condition to occur at the power controller The thermostat will close once the heater cools down to a safe operating temperature approximately 140 F An alarm condition signal can be configured within the power control system to alert the user that the alarm condition exists i e signal light signal horn etc Additionally the power 10 e 480V SINGLE PHASE TIR TSTAT 662 3 6 7 10111617 159 4 812 Eg 240V 384V E SINGLE PHASE LI TSTAT D 16 17 13579 2458102 11 control system can be configured so that electrical power is removed from the Model 5209 if the thermostat reaches an overheat condition 480V 3 PHASE TSTAT 662 36 7 10111617
13. itting located at the center of the heater is the cooling air inlet port All three fittings accept z 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 5209 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 installation for the Model 5209 heater Note Fitting plugs are placed into the two water coolant fittings as shipped from the factory Both of these plugs must be removed from their respective fittings prior to inserting the flexible tubing These plugs can either be kept for future use or discarded See Figure 4 1 for detail Figure 4 1 Electrical Connections Each of the six T3 lamps of the Model 5209 is electrically wired to intermediate individual terminal blocks within the heater In turn each terminal block along with the heater safety thermostat and heater grounding wires are wired to a 19 pin connector mounted to the heater cover see Figure 4 2
14. lower 20 0 57 20 0 57 20 0 57 CFM M P min 6 2 PSI QUNTING LOCATIONS 4 12 7 AIR INLET TOP VIEW 0 50 IN O D TUBE 12 1 WATER PORT 2 FRONT VIEW END VIEW Figure 6 1 Model Number Dimensions Inches mm A 5209 05 1 8 45 7 5 5 139 7 9 10 231 1 5209 10 3 73 94 7 7 00 177 8 14 45 367 0 5209 16 3 73 94 7 12 63 320 8 20 08 510 0 Note The height and width dimensions are identical on all three sizes of the Model 5209 15 Qe30 ps OLS SUPPLY 1 2 INCH 0 0 TUBING REGULATOR LENGTH L FILTER 0 30 PSI 5209 HEATER Figure 6 2 FRONT VIEW BACK VIEW 5 L im 2 4 1 12 128 41 BOTTOM VIEW Figure 6 3 Model Product Description 5209 High Temperature Infrared Heater Code Lighted Length 05 5 Inches 127 mm 10 10 Inches 254 mm 16 16 Inches 406 mm Code Electrical Cable Length 10 10 Feet 3 m 20 20 Feet 6 m N None Code Optional Equipment Quartz Window JB Electrical Junction Box PC TCP Power
15. nnen seen a 6 Mounting the Heater 6 Operating Instruetions as ea ee 8 Heater Cooline Connections ne u 8 Electrical oen 9 Heater NR M 10 Maintenance amp Troubleshooting y dedito d RE 12 Quartz Window Cleaning and 1 bee iter I e Botero 14 CIeanmg the Rerlectot end a 14 Dimensions and Specifications coo a eek er 15 Spare amp Replacement Parts ss ach 19 1 Introduction General Description The Model 5209 Hi TempIR heater is designed to provide high intensity infrared heat onto localized areas Typical applications for these heaters include Aerodynamic heating simulation Thermal stress testing Heating tensile and fatigue test specimens Semiconductor wafer processing Chemical processing Stress relieving Metal brazing processes The Model 5209 includes the following major components Heater Module The heater consists of a specular aluminum reflector that directs the infrared energy generated by six ceramic end seal T 3 style quartz halogen lamps factory installed in the heater Heated lengths of 5 10 and 16 inches 127 254 and 406 mm are offered for the Model 5209 Additional lamps can be ordered separately from the heater Water Cooling Adequate cooling water is required during operation of the Model 5209 Flexibl
16. or 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 5209 reflector 1 Remove the lamps as described in Section 5 2 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 3 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 this inability to adversely affect the aluminum reflector 4 Replace the lamps quartz window if so desired and the heater end covers as outlined in Section 5 Lamp Removal Replacement Installation 14 6 Dimensions and Specifications Specifications 5209 05 5209 10 5209 16 Weight pounds kg 7 5 3 4 10 4 5 12 8 5 8 Lamp Type QIH240 1000R12 QIH240 2000R12 QIH384 3200R12 Lighted length Inches mm 5 127 11 280 16 406 Rated Voltage 240 240 384 Total Power Dissipated at 6 12 19 2 Rated Voltage kW Cooling Water Flow GPM 1 0 3 8 1 5 5 7 2 25 8 5 1 min Cooling Air Flow SCFM 4 0 11 3 0 PSI 4 0 11 1 0 PSI 4 0 11 1 0 PSI M P min see also fig 3 2 With a Regenerative b
17. ps or adjacent parts Electrical Safety There is danger of electrical shock when servicing the heater ICAUTION Observe all applicable local and national electrical codes and a safe electrical ground system is installed before attempting to operate the heater Refer to the Section 5 for proper installation procedures IWARNING 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 Fire Safety 1 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 Remove all solids liquids and gases that burn easily from the area around the heater Know where the nearest fire extinguisher is located and how to use it Know how to put our fire from all the types of material near the heater 3 Installation Unpack and Check for Damage Remove the model 5209 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 Mounting the Heater The Model
18. s disconnected Continuous Operation The formed stainless steel and extruded aluminum construction of the Model 5209 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 5209 ordered with the PC option is a complete heating solution designed with a number of features including heater on off control switching potentiometer local control and mechanically interlocked doors with main power disconnect switch Heater over temperature indicators a digital voltmeter and system cooling on off control switches with indicator lamps are also included The complete system allows the end user to easily install both the heater and controller within the given application The heater is supplied with a 10 foot 8m removable electrical cable and is terminated within Model 5209 Junction Box A separate 30 foot 9 1 m electrical cable connects the Junction Box to the power control system either the Model 915 or Model 935 ControllR This plug and play feature simplifies installation for the end user and allows the heating system to be put into use very quickly 2 Safety GENERAL The Model 5209 heater is designed for safe operation Nevertheless installation maintenance and operation of the heater can be dangerous for a
19. ting temperature Optional Quartz Window A quartz window can be ordered along with each size of the Model 5209 When installed in the heater the quartz window protects the aluminum reflector and lamps from contaminants released in the heating process resulting in maximum efficiency of the heater Optional Electrical Junction Box An optional electrical junction box can be ordered with the Model 5209 The junction box accommodates all of the wiring present within the removable electrical cable and is designed to accept either a 240 or 480 volt supply source Optional Power Control System The Model 5209 can be ordered with the PC option This configuration consists of the heater removable electrical cable wired to a junction box and a Research Inc Model 915 single phase or Model 935 three phase SCR based power control system also wired to the junction box This power control system is designed to match the electrical supply needs of the heater Please see the Model 915 or Model 935 ControllR product data sheet for further detail Standard Features The design and functionality of the Model 5209 supplies a variety of features and related 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 i
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