Chromalox DS-50600 Electric Heater User Manual
Contents
1. 2 and 3 located in disconnect switch housing Thread these three 3 leads through the nipple Attach leads to the terminals indicated on the heater wiring label located on the cover of the heater If using for single phase cap off lead marked 3 8 Attach conduit to the opening in the disconnect switch housing Connect leads to terminal block 9 Inspect all wiring to make sure all connections are tight adequate electrical clearances exist and all electrical practices are met 10 Install both covers INSTALLATION INSTRUCTIONS Cover Step 5 3 Pole Disconnect Switch 3 Pole Terminal Block w Ground Step 11 Chase Nipple and Gasket Step 6 Mounting Bracket Step 4 3 8 Lockwasher and Nut 4 Drawing shows 6 kW heater 13 5 kW heater steps are identical INSTRUCTIONS FOR INSTALLING DISCONNECT SWITCH ON 6 AND 13 5 KW PORTABLE RADIANT HEATERS 1 Addition of the disconnect switch assy must be done by a qualified electrician 2 The disconnect switch kit includes the following parts Verify that all parts are included if not contact the Chromalox Service Dept 1 Disconnect Switch Assy 2 Mounting Bracket 3 Hardware Kit Two 3 8 Lockwashers Two 3 8 Nuts One Self Tapping Screw One Gasket for Cord Fitting Supplied Separately 3 Remove the screws in the heater terminal box Remove cover 4 Place mounting bracket over 3 8 studs as shown Place lockwashers on s2. MONITOR p TOGGLE SWITCH SUPPLY 9 TO TERMINALS No NSIDE HEATER CONTACTOR JUNCTION BOX POWER LEADS MUST SEE NOTES PASS THROUGH CURRENT TRANSFORMER POSITION OF GROUND FAULT MONITOR ATTACHED TO AUXILLARY TERMINALS 3 2 1 PRI SIDE TRANSFORMER CONNECTION 208V BLK AND RED 240V BLK AND ORG NOTES 277 BLK AND BRN 1 USE 90 DEG MIN WIRING 380V BLK AND VIOLET 2 USE COPPER CONDUCTORS ONLY 480V BLK AND BLK RED 3 VERIFY THAT VOLTAGE OF STAR TG 600V BLK AND GRAY G MATCHES VOLTAGE OF HEATER UNUSED LEADS CAPPED OFF ACK WHITE TRANSFORMER Fig 2 GROUND FAULT MONITOR TOGGLE TIPOVER TIPOVE SWITCH SWITCH SWITCH O Q O oO NC TO TERMINALS co INSIDE HEATER 9 2 JUNCTION BOX NO CONTACTOR IE POWER LEADS MUST L3 PASS THROUGH CURRENT L2 SEE NOTES TRANSFORMER POSITION Li AUXILLARY TERMINALS OF GROUND FAULT N MONITOR ATTACHED PRI SIDE TRANSFORMER CONNECTION 208V BLK AND RED 240V BLK AND ORG 0 277V BLK AND BRN 6
3. element by applying half of the rated voltage for one hour 3 Rebuss elements re energize heater flip toggle switch back and forth one time to reset GF sensor Close cover 1 Each element to have at least 10 Meg terminal to sheath 2 If element does have at least 10 Meg No dry out element by applying half of the rated voltage for one hour 3 Rebuss elements re energize heater flip toggle switch back and forth one time to reset GF sensor Do you want to reduce future down time and maintenance costs 1 Replace all elements 2 Flip toggle switch back and forth one time to No reset GF sensor Call Chromalox Service Dept 1 800 368 2493 Does the heater operate Close cover INSTALLATION INSTRUCTIONS 3 POLE CONTACTOR OPENING FOR 1 CORD FITTING STEP 11 CHASE NIPPLE AND GASKET STEP 6 SELF TAPPING SCREW STEP 8 4 HEAT NO HEAT MOUNTING BRACKET STEP 4 VIEW SHOWN WITH TIP OVER SWITCH ASSY COVER REMOVED Drawing shows 6 kW heater 13 5 kW heater steps are identical INSTRUCTIONS FOR INSTALLING STAR TIP AND STAR TG ON 6 AND 13 5 KW PORTABLE RADIANT HEATERS COVER STEP 3 3 8 LOCKWASHER AND NUT STEP 4 1 Addition of the tip over switch assy must be done by a qualified electrician 2 The tip over switch assy includes the following parts Verify that all parts are included if no
4. Chromalox Installation Operation SERVICE REFERENCE omision 4 secon O REFERENCE Supersedes PG436 1 PG436 2 RENEWAL PARTS IDENTIFICATION 161 304901 004 DATE JUNE 2010 DS 50600 STAR GF STAR TIP and STAR TG Kits For Adding Optional Kits to STAR Radiant Heaters Model DS50600 Model STAR TIP STAR GF STAR TG Always check to make certain the voltage rating of the kit AWARNING matches voltage rating of heater See ELECTRIC SHOCK HAZARD Disconnect all power to heater before installing or servicing kit s Failure to do so could result in personal injury or property damage Kit s must be installed by a qualified person in accordance with the National Electrical Code NFPA 70 GENERAL To use this instruction sheet from Table 1 select the Installation The kits are add on options to STAR Radiant Heaters The Instructions by matching the Kit Model to the Heater Model If a installation and renewal parts identification for the heater is cov match does not exist consult Factory ered in the instruction sheet provided with the heater SAVE BOTH COPIES OF THE INSTRUCTION SHEET Table 1 Kit Model Used with Heater Model Kit Function Installation Instructions Wiring Diagram DS 50600 Fixed STAR 06A STAR 14A Adds Integral Disconnect Switch See Page 2 DS 50600 Portable STAR 06A and STAR 14A Adds Integral Disconnect Switch See Page 3 STAR GF All Fixed STAR Adds Wall Mounted Ground Fault Sensor See Page 4 S
5. NOTES 480V BLK AND BLK RED 1 USE 90 DEG C MIN WIRING 380V BLK AND VIOLET z 2 USE COPPER CONDUCTORS ONLY 600V BLK AND GRAY 3 VERIFY THAT VOLTAGE STAR TG UNUSED LEADS CAPPED OFF o G MATCHES VOLTAGE OF HEATER WHITE TRANSFORMER Fig 4 RENEWAL PARTS IDENTIFICATION Disconnect DS Shaft Cover U Shaped Term Block Term Block Switch Gasket Gasket Clamp Cont Sect DS 506008 292 303472 007 132 304689 001 132 304879 002 056 304884 004 STAR GF 8 Toggle Toggle Switch Ground Fault Tip Over End Sect Switch Boot Contactor Sensor Switch 072 121651 062 303 052241 002 303 052241 001 292 046123 001 024 052539 001 072 306110 008 292 304695 001 072 121651 062 Limited Warranty Please refer to the Chromalox limited warranty applicable to this product at http www chromalox com customer service policies termsofsale aspx Chromalox PRECISION HEAT AND CONTROL 2150 N RULON WHITE BLVD OGDEN UT 84404 Phone 1 800 368 2493 www chromalox com TA EF Litho in U S A
6. TAR TIP Portable STAR 06A STAR 14A Adds Tip Over Shut Down See Page 5 STAR TG Portable STAR 06A and STAR 14A Adds Tip Over Shut Down with Ground Fault Sensor See Pages 5 and 6 2008 Chromalox Inc INSTALLATION INSTRUCTIONS Cover Step 4 Terminal Block w Ground Opening for 1 Conduit Fitting Step 8 3 Pole Disconnect Switch On Off Handle Chase Nipple and Gasket Step 5 Step 3 Drawing shows 6 kW heater 13 5 kW heater steps are identical INSTRUCTIONS FOR INSTALLING DISCONNECT SWITCH ON 6 AND 13 5 KW FIXED RADIANT HEATERS 1 Addition of the disconnect switch assy must be done by a qualified electrician 2 The disconnect switch kit includes the following parts Verify that all parts are included if not contact the Chromalox Service Dept 1 Disconnect Switch Assy 2 Mounting Bracket Not Used 3 Hardware Kit Not Used Two 3 8 Lockwashers Two 3 8 Nuts One Self Tapping Screw One Gasket for Cord Fitting Supplied Separately 3 Remove the screws in the heater terminal box Remove cover 4 Remove cover from disconnect switch assy using same method as Step3 5 Remove Chase nipple and gasket from opening end of disconnect switch assy Slide Chase nipple through hole in heater terminal box and then gasket over threads 6 Thread Chase nipple into threaded coupling Wrench tighten nipple 7 Uncoil three 3 leads marked 1
7. TROUBLESHOOTING DIAGRAM Is th initial ation Is this the first time heater is used for the season Is the set point of the GF sensor set at a value less than 03 amps No Call Chromalox Service Dept 1 800 368 2493 This condition indicates at least one element is about to fail Did the problem occur after working properly during part of this heating season No Unbuss wiring check insulation resistance Yes Unbuss wiring check insulation resistance 1 Turn set point dial clockwise to 03 amps 2 Flip toggle switch mounted ontop of enclosure back and forth one time this resets the GF sensor No Does the heater operate Close cover on each element 1 Each element to have at least 10 Meg terminal to sheath 2 If element does not have at least 10 Meg dry out element by applying half of the rated voltage for one hour 3 Rebuss elements re energize heater flip toggle switch back and forth one time to reset GF sensor on each element Close all covers 1 Each element to have at least 10 Meg terminal to sheath Do you want to 2 If element does not have at least 10 Meg reduce future No dry out element by applying half of the ro down time and gt rated voltage for one hour maintenance 3 Rebuss elements re energize heater fl
8. ber and length of the heat ing elements See Table 2 3 See Instruction Sheet PG434 provided with heater for IMPORTANT INSTRUCTIONS and WIRING 4 Using the STAR GF as a template mark mounting holes on wall Use an anchoring method adequate to support the weight 5 Wire between STAR GF and heater wire to terminal block Service entrance wiring to be made to contactor connectors For wire gage see Table 1 of PG434 6 The ground fault sensor has been factory set at 03 Amps DO NOT CHANGE THE SETTING STAR GF Mounting Dimensions 8 1 2 6 i 3 4 Table 2 Heater Model STAR 02A STAR 05A STAR 06A STAR 14A Max No of Heaters 10 3 4 10 5 16 Dia a MAINTENANCE The Chromalox STAR GF ground fault sensor provides a reli able and cost effective method for sensing ground faults The pur pose is to monitor for ground faults sense potential heater failure symptoms and to protect equipment The current carrying wires are routed through the current transformer on the control When ground current reaches the level set by the trip point adjustment 03 Amps the relay trips illu minates the tripped LED and provides an output signal which de energizes the magnetic contactor AWARNING ELECTRIC SHOCK HAZARD Disconnect all power to heater before installing or servicing kit s Failure to do so could result in personal injury or property damage Ki
9. ip costs toggle switch back and forth one time to reset GF sensor 1 Replace all elements 2 Flip toggle switch back and forth one time to No Does the reset GF sensor heater operate Call Chromalox Service Dept 1 800 368 2493 Close all covers Does the heater operate Yes Close all covers WIRING For applicable wiring diagram see Table 1 TERMINAL BLOCK TOGGLE TIPOVER SWITCH SWITCH NOTES A 1 USE 90 DEG MIN WIRING TIPOVER 2 USE COPPER CONDUCTORS ONLY 3 TO MAINTAIN THE ENVIRONMENTAL _ H 5 RATING OF THIS ENCLOSURE USE CONTACTOR O ONLY UL LISTED OR RECOGNIZED 3 Blo NOTES 2 LIQUID TIGHT CONDUIT HUBS 2 1 USE 90 DEG MIN WIRING DISCONNECT 1 2 USE COPPER CONDUCTORS ONLY SWITCH 70 TERMINALS _ 3 VERIFY THAT VOLTAGE OF STAR TIP TO TERMINALS INSIDE HEATER MATCHES VOLTAGE OF HEATER INSIDE HEATER JUNCTION BOX JUNCTION BOX do PRI SIDE TRANSFORMER CONNECTION Fig 1 208V BLK AND RED 240V BLK AND ORG G 277V BLK AND BRN 380V BLK AND VIOLET TRANSFORMER 480V BLK AND BLK RED 600V BLK AND GRAY UNUSED LEADS CAPPED OFF Fig 3 GROUND FAULT
10. t contact the Chromalox Service Dept 1 Tip Over Switch Assy 2 Mounting Bracket 3 Hardware Kit Two 3 8 Lockwashers Two 3 8 Nuts Two Self Tapping Screw One Gasket for Cord Fitting Supplied Separately 3 Remove the screws in the heater terminal box Remove cover 4 Place mounting bracket over 3 8 studs as shown Place lockwashers on studs and secure in place with 3 8 nuts 5 Remove cover from tip over switch assy using same method as Step 3 6 Remove Chase nipple and gasket from open end of tip over switch assy Slide Chase nipple through hole in heater terminal box and then gasket over threads 7 Thread Chase nipple into threaded coupling Hand tighten nipple 8 Line up hole in bottom of tip over switch with hole in mounting bracket Tap 10 32 x 1 2 long screws into mounting bracket 9 Wrench tightened Chase nipple installed in Step 6 10 Uncoil three 3 leads marked 1 2 and 3 located in disconnect switch housing Thread these three 3 leads through the nipple Wire nut leads of tip over switch to leads of heater If using for single phase cap off lead marked 3 11 Attach cord assembly to the opening in the tip over switch housing Connect leads of cord to the contactor 12 Inspect all wiring to make sure all connections are tight adequate electrical clearances exist and all electrical practices are met 13 Install both covers MAINTENANCE The Chromalox STAR TG
11. t s must be installed by a qualified person in accordance with the National Electrical Code NFPA 70 If heating element s fail to operate 1 Open door of enclosure DANGER Hazard of Electric Shock If Tripped indicator is on this indicates one or more heating elements are about to fail Disconnect power and fol low the GF Troubleshooting Diagram below 2 If the Tripped indicator is not on check for blown fuses or failed components within the heater s electrical system GF TROUBLESHOOTING DIAGRAM START Tripped Indicator Light is On y Is this the initial installation Is this the first time heater is used for the season Is the set point of the GF sensor set at a value less than 03 amps Call Chromalox Service Dept 1 800 368 2493 This condition indicates at least one element is about to fail Did the problem occur after working properly during part of this heating season Unbuss wiring check insulation resistance on each element Yes 1 Turn set point dial clockwise to 03 amps 2 Flip toggle switch mounted ontop of enclosure back and forth one time this resets the GF sensor Does the heater operate Close cover Unbuss wiring check insulation resistance on each element 1 Each element to have at least 10 Meg terminal to sheath 2 If element does not have at least 10 Meg dry out
12. tip over cutout with ground fault sensor provides a reliable and cost effective method for sensing ground faults and to shut off the heater in case of tip over The pur pose of the ground fault control is to monitor for ground faults sense potential heater failure symptoms and to protect equipment The current carrying wires are routed through the current transformer on the control When ground current reaches the level set by the trip point adjustment 03 amps the relay trips illumi nates the tripped LED and provides an output signal which de energizes the magnetic contactor ELECTRIC SHOCK HAZARD Disconnect all power to heater before installing or servicing kit s Failure to do so could result in personal injury or property damage Kit s must be installed by a qualified person in accordance with the National Electrical Code NFPA 70 If heating element s fail to operate Open door of enclosure DANGER Hazard of Electric Shock If Tripped indicator is not on check for blown fuses or failed electrical components in the heater s electrical system includ ing the tip over trip mechanism then this indicates one or more heating elements are about to fail Check pendulums on the tip over switch mechanisms to be sure they are not blocked If the Tripped indicator is on then this indicates one or more heating elements are about to fail Disconnect power and fol low the GF Troubleshooting Diagram below 1 2 TG
13. tuds and secure in place with 3 8 nuts 5 Remove cover from disconnect switch assy using same method as Step 3 6 Remove Chase nipple and gasket from opening end of disconnect switch assy Slide Chase nipple through hole in heater terminal box and then gasket over threads 7 Thread Chase nipple into threaded coupling Hand tighten only 8 LIne up hole in bottom of disconnect switch housing with hole in mounting bracket Tap 10 32 x 1 2 long screw into mounting bracket 9 Wrench tighten Chase nipple installed in Step 6 10 Uncoil three 3 leads marked 1 2 and 3 located in disconnect switch housing Thread these three 3 leads through the nipple Attach leads to the terminals indicated on the heater wiring label located on the cover of the heater If using for single phase cap off lead marked 3 11 Attach cord assy to the opening in the disconnect switch housing Connect leads of cord to termi nal block 12 Inspect all wiring to make sure all connections are tight adequate electrical clearances exist and all electrical practices are met 13 Install both covers INSTRUCTIONS FOR INSTALLING WALL MOUNTED STAR GF 1 Check voltage on heater nameplate and STAR GF to make cer tain voltages are the same If voltages do not match consult factory 2 The STAR GF will provide ground fault protection for STAR Radiant heaters The number of heaters serviced by one 1 STAR GF is dependent on the num
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