PG434-4
(Supersedes PG434-3)
SEPTEMBER, 2009
Type STAR Radiant Heater
For Fixed Overhead Installations
2.0 kW
4.5 kW
B
11-9/16"
11-9/16"
15-1/2"
15-1/2"
55-3/4"
33-1/4"
Figure 1
6.0 kW
13.5 kW
11-1/2"
23-5/8"
11-1/2"
23-5/8"
32-1/2"
55-5/8"
Figure 2
BTU
Specifications – Table 1
Amperage
Dimensions (In.)
B Width
Wire Ga. (Min.)
Model
Figure
Volts
KW
1 Phase
3 Phase
A Length
D Depth
1 Phase
3 Phase
STAR-02A-11-F
STAR-02A-81-F
STAR-02A-21-F
STAR-02A-71-F
STAR-02A-41-F
STAR-02A-61-F*
120
208
240
277
480
600
1.5
2
12.5
9.6
8.3
7.2
4.2
3.3
NA
NA
NA
NA
NA
NA
5118
6824
6824
6824
6824
6824
14
14
14
14
14
14
NA
NA
NA
NA
NA
NA
1
2
33-1/4
15-1/2
11-9/16
2
2
2
STAR-05A-81-F
STAR-05A-21-F
STAR-05A-71-F
STAR-05A-41-F
STAR-05A-61-F*
208
240
277
480
600
4.5
4.5
4.5
4.5
4.5
21.6
18.8
15.9
9.4
NA
NA
NA
NA
NA
15354
15354
15354
15354
15354
12
12
14
14
14
NA
NA
NA
NA
NA
1
2
2
55-3/4
32-1/2
55-5/8
15-1/2
23-5/8
23-5/8
11-9/16
11-1/2
11-3/4
7.5
STAR-06A-83-F
STAR-06A-23-F
STAR-06A-71-F
STAR-06A-43-F
STAR-06A-63-F*
208
240
277
480
600
6
6
6
6
6
28.8
25.0
21.7
12.5
10.0
16.7
14.4
—
7.2
5.8
20472
20472
20472
20472
20472
10
10
10
12
12
12
12
—
12
12
STAR-14A-83-F
STAR-14A-23-F
STAR-14A-71-F
STAR-14A-43-F
STAR-14A-63-F*
208
240
277
480
600
13.5
13.5
13.2
13.5
13.5
NR
NR
47.7
28.1
22.5
37.5
32.5
—
16.2
13.0
46062
46062
45038
46062
46062
NR
NR
8
12
12
10
10
12
12
* Not UL or CSA
NA - Not Available
NR - Not Recommended
© 2010 Chromalox, Inc.
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WIRING
3. The heater connection points are located in the gasketed terminal
enclosure. To remove cover, remove 4 screws on the cover.
Remove the cover to expose wiring connection points.
4. Agreen ground terminal is provided in the bottom of the enclosure.
The ground wire should be connected before other connections are
made.
ELECRIC SHOCK HAZARD. Disconnect all power
before installing or servicing heater. Failure to do so
could result in personal injury or property damage.
Heater must be effectively grounded in accordance
with the National Electrical Code, NFPA 70.
5. Refer to Table 1 for proper entrance wiring size.
6. Heater can be wired with rigid or flexible conduit.
7. All 3 element heaters are factory pre-wired for 3-phase delta oper-
ation. Some units can be converted to single phase operation by
changing the wiring. Refer to Table 1 for those heaters that can be
converted to single phase. The appropriate wiring diagram (Figure
3) is also located on the bottom of the enclosure.
All electrical wiring must be done by a qualified per-
son in accordance with National Electrical Code (NEC)
and meet all state and local regulations.
1. Use heater only at the voltage specified on the nameplate.
2. Branch circuit wire for connection to heater must be at least 90°C
wire. Use copper conductors only.
INSTRUCTIONS FOR FIELD CONVERSION FROM 3 PHASE TO 1 PHASE:
1. Remove nuts from all terminals.
2. Remove all pigtail leads and hat shaped buss bar.
3. Remove end of leadwire on terminal 5 and slip onto terminal 4.
4. Remove leadwire attached to instruction sheet and connect between terminals 4 and 6.
5. Install hat shaped buss bar between terminals 3 and 5.
6. Place pigtail lead marked “L1” on to terminal 2 and pigtail lead marked “L2” on to terminal 6.
7. Install nuts.
8. Connect entrance wiring to pigtail leads “L1” and “L2”. Connect ground to screw provided.
9. Inspect to make sure wiring is per “Single Phase Wiring” above.
OPTIONAL ACCESSORIES
Chromalox STAR series radiant heaters can be field modified
by adding optional kits. Refer to Chart A to select the proper kit.
Hanger Kit
Hanger kits include 24 feet of chain and four S hooks to mount
the unit in a fixed overhead position using the universal mounting
brackets included on the heater. This kit allows installation dis-
tances from the ceiling of 2 feet to 6 feet. See installation diagram
Fig. 4 on page 2.
Portable Cart Kit
The portable cart kit can be used to convert a fixed overhead
unit into a portable heating device where a fixed installation is not
required. This kit includes wheels, legs, handle, grill(s), baffle (if
reqd) and all of the necessary hardware to complete the modifica-
tion. See instruction bulletin PG435 for details.
Cord Kits (Portable Only)
Cord kits consist of 25 feet of 90°C cable and a right angle cord
fitting which can connect directly to the heater terminal box or dis-
connect switch (if used). See installation bulletin PF491 for details
Grill Kit
The grill kit consists of one (1.5, 2, 4.5 and 6 kW) or 2 grill sec-
tions (13.5kW) and hardware to protect personnel from coming
into contact with hot radiant heating elements. See instruction bul-
letin PG437 for details.
Tip Over and Ground Fault Kits
STAR TIP Series Kit attaches to portable heater and de-ener-
gizes the heater in the event it is tipped over.
STAR-GF Series Kit mounts to wall that de-energizes heater
prior to element failure.
Disconnect Kit
The disconnect kit consists of a complete assembly consisting
of a disconnect switch (3 Pole), power terminal block and all hard-
ware to complete the installation. This kit can be mounted to both
the fixed, overhead heater or the portable heater; see instruction
bulletin PG436 for details.
STAR-TG Kit combines the tip over and ground fault feature for
portable heaters. See installation bulletin PG436.
3
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OPTIONAL ACCESSORIES
Chart A – Kit Selection Guide
Grill
Kit
Disconnect
Kit
Hanger
Kit
Wall Mount
Ground Fault
Portable
Cart Kit**
Model
STAR-02A-11-F
STAR-02A-81-F
STAR-02A-21-F
STAR-02A-71-F
STAR-02A-41-F
STAR-02A-61-F
STAR-05A-81-F
STAR-05A-21-F
STAR-05A-71-F
STAR-05A-41-F
STAR-05A-61-F
STAR-06A-83-F
STAR-06A-23-F
STAR-06A-71-F
STAR-06A-43-F
STAR-06A-63-F
STAR-14A-83-F
STAR-14A-23-F
STAR-14A-71-F
STAR-14A-43-F
STAR-14A-63-F
PCN 111878
PCN 111878
PCN 111878
PCN 111878
PCN 111878
PCN 111878
PCN 111894
PCN 111894
PCN 111894
PCN 111894
PCN 111894
PCN 340638
PCN 340638
PCN 340638
PCN 340638
PCN 340638
PCN 340857
PCN 340857
PCN 340857
PCN 340857
PCN 340857
NA
NA
PCN 340777
PCN 340785
PCN 340793
PCN 340806
PCN 340814
PCN 340777
PCN 340785
PCN 340793
PCN 340806
PCN 340814
PCN 340777
PCN 340785
PCN 340793
PCN 340806
PCN 340814
PCN 340777
PCN 340785
PCN 340793
PCN 340806
PCN 340814
NA
NA
NA
NA
NA
PCN 340620
PCN 340620
PCN 340620
PCN 340620
PCN 340620
PCN 340830
PCN 340830
PCN 340830
PCN 340830
PCN 340830
PCN 340849
PCN 340849
PCN 340849
PCN 340849
PCN 340849
PCN 340662
PCN 340654
** Includes Grill(s)
MAINTENANCE
4. Remove retainer screw located on the reflector at the terminal end.
5. Loosen (2), 3/8" nuts from the terminal box bracket located on the
back of the heater and slide the entire heating element assembly
out of the reflector assembly.
ELECRIC SHOCK HAZARD. Disconnect all power
before servicing or replacing heating elements.
6. Remove wires and jumper straps as required to replace the failed
heating element(s).
7. Remove bulkhead fitting nuts and washers.
8. Remove failed element and replace with a new element. Replace
only with genuine Chromalox "Arctic End" elements. Use of other
elements will cause excess temperatures inside terminal box.
9. Place gasket on the bulkhead fitting and insert terminals and fit-
tings into the element holes in the terminal box.
10. Place washers and nuts on bulkhead fittings and tighten.
11. Replace wiring and jumper straps (see Fig. 1).
12. Reassemble by following the reverse procedures
(steps 5 through 1).
BURN HAZARD. Hot surfaces. Allow sufficient time for
heater to cool before serviceing or cleaning heater.
The reflectors should be kept clean to obtain the maximum
radiant output.
Element Replacement
1. Remove Terminal Box Cover.
2. Disconnect lead wires from heater terminals and disengage box
from conduit /cable fitting.
3. Remove safety grills (if installed).
4
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RENEWAL PARTS IDENTIFICATION
Element Housing
Terminal Box
Gasket
Model
Element***
PCN 106059
PCN 106067
PCN 106075
PCN 106083
PCN 106091
PCN 106104
PCN 106403
PCN 106411
PCN 106796
PCN 106964
PCN 106972
PCN 106067
PCN 106075
PCN 106083
PCN 106091
PCN 106104
PCN 106403
PCN 106411
PCN 106796
PCN 106964
PCN 106972
Reflector
Safety Screen
PCN 111878
PCN 111878
PCN 111878
PCN 111878
PCN 111878
PCN 111878
PCN 111894
PCN 111894
PCN 111894
PCN 111894
PCN 111894
PCN 340638
PCN 340638
PCN 340638
PCN 340638
PCN 340638
PCN 340857
PCN 340857
PCN 340857
PCN 340857
PCN 340857
STAR-02A-11-F
STAR-02A-81-F
STAR-02A-21-F
STAR-02A-71-F
STAR-02A-41-F
STAR-02A-61-F
STAR-05A-81-F
STAR-05A-21-F
STAR-05A-71-F
STAR-05A-41-F
STAR-05A-61-F
STAR-06A-83-F
STAR-06A-23-F
STAR-06A-71-F
STAR-06A-43-F
STAR-06A-63-F
STAR-14A-83-F
STAR-14A-23-F
STAR-14A-71F
STAR-14A-43-P
STAR-14A-63-P
132-304879-004
132-304879-004
132-304879-004
132-304879-004
132-304879-004
132-304879-004
132-304879-004
132-304879-004
132-304879-004
132-304879-004
132-304879-004
132-304879-003
132-304879-003
132-304879-003
132-304879-003
132-304879-003
132-304879-003
132-304879-003
132-304879-003
132-304879-003
132-304879-003
234-891755-004
234-891755-002
234-891755-004
234-891755-002
*** Includes element supports
Parts Common to All Models:
Bulkhead fitting gasket . . . . . . . . . . . . . . . 132-895735-008
Bulkhead fitting washer . . . . . . . . . . . . . . . 328-890675-014
Bulkhead fitting nut . . . . . . . . . . . . . . . . . . 200-890615-031
Element Support . . . . . . . . . . . . . . . . . . . . . 291-304869-002
5
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Limited Warranty:
Please refer to the Chromalox limited warranty applicable to this product at
2150 N. RULON WHITE BLVD., OGDEN, UT 84404
Phone: 1-800-368-2493
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