Chromalox Electric Heater PG412 10 User Manual

®
Chromalox  
Installation, Operation  
DIVISION  
SALES  
SECTION  
4
RADD  
and  
(Supersedes PG412-9)  
PG412-10  
REFERENCE  
RENEWAL PARTS IDENTIFICATION  
161-026681-001  
DATE  
DECEMBER, 2008  
Specifications  
!
The Safety Alert Symbol  
sonal injury.  
is used to indicate a risk of per-  
A
B
Model No.  
Volts  
kW  
Overall Length Heated Length  
Please familiarize yourself with these instructions before  
attempting to install or operate this Radiant Heater.  
RADD-2164  
RADD-2164V  
120 or 240  
208 or 275  
120 or 240  
208 or 275  
208 or 275  
240 or 480  
208 or 275  
240 or 480  
208 or 275  
240 or 480  
208 or 275  
240 or 480  
208 or 275  
240 or 480  
208 or 275  
240 or 480  
1.6  
24-3/8  
30-5/8  
35-7/8  
46-5/8  
53-7/8  
61-3/8  
65-7/8  
73-3/4  
79-7/8  
85-3/4  
106  
16-1/2  
22-3/4  
28-5/16  
38-1/2  
45-7/16  
53-3/8  
58-1/4  
65-3/4  
72-1/4  
78  
RADD-3224  
2.2  
2.6  
3.6  
4.3  
5.0  
5.4  
6.0  
6.7  
7.2  
9.0  
RADD-3224V  
RADD-3264V  
RADD-3264  
RADD-4364V  
RADD-4364  
RADD-5434V  
RADD-5434  
Type RADD Electric  
Radiant Heaters  
RADD-5504V  
RADD-5504  
RADD-6544V  
RADD-6544  
RADD-6604V  
RADD-6604  
B
A
RADD-7674V  
RADD-7674  
RADD-7724V  
RADD-7724  
RADD-8904V  
RADD-8904  
RADD-7604X10  
RADD-7604X13  
RADD-7604X9A  
RADD-7724X38  
208 or 275  
240 or 480  
208 or 275  
240 or 480  
208 or 275  
240 or 480  
Before Installing:  
1. Open carton and remove heater at the place of installation.  
Mounting clamps are in parts bag in carton.  
97-1/2  
2. Check nameplate volt and watt rating against your power sup-  
ply voltage and heating requirements of your installation. This  
nameplate is located on one end of the heater.  
240 or 480  
240 or 480  
240 or 480  
240 or 480  
8.0  
10  
11  
13  
114-1/8  
141  
160-5/8  
185-5/8  
106  
132  
150  
174  
The system designer is responsible for the safety  
of this equipment and should install adequate  
back-up controls and safety devices with their  
electric heating equipment. Where the conse-  
quences of failure could result in personal injury or  
property damage, back-up controls are essential.  
INSTALLATION  
Clamp assembly may be attached to heater by sliding over end  
or by snapping over top of extruded frame section at any point  
along its length. (see Fig. 2) For proper heater support, the  
maximum distance between clamps must not exceed 48”. On  
extra-long heaters, more than two clamps are furnished.  
3. Mounting Holes — When heaters are mounted adjacent to  
each other in the same plane, note that distance between  
mounting holes on framing to support heaters will be 3-11/16”  
minimum. When heaters are not in the same plane, i.e., set at  
an angle to one another, distance between mounting holes in  
framing will be either greater or less than 3-11/16”.  
ELECTRIC SHOCK HAZARD. Disconnect all power  
before installing or servicing heater. Failure to do  
so could result in personal injury or property dam-  
age. Heater must be installed or serviced by a  
qualified person in accordance with the National  
Electrical Code, NFPA 70.  
1. These radiant heaters are designed for indoor installation only.  
2. Mounting Clamps — Mount heaters by using the mounting  
clamp and 3/8” bolt assembly.  
4. Framing Where an extensive installation is being made, the  
use of continuous slot metal framing manufactured by several  
concerns will be of assistance in saving time and money. The  
framing is reusable.  
(Interlocking Connectors  
Discontinued)  
Figure 1 — Heater Parts and Dimensions  
Figure 2  
© 2010 Chromalox, Inc.  
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WIRING (cont’d.)  
11. Delta Connections — When heaters occur in multiples of  
three, they may be connected to, and balanced across, three-  
phase lines. The most commonly used connection is the delta  
connection illustrated in Fig. 5. Three phase Delta connections  
to minimize inductive effect in conduits are made per this dia-  
gram. The rule: run all 3 three-phase conductors in the same  
conduit as far as possible. For single-phase, run only two con-  
ductors and follow the same rule.  
Figure 5  
OPERATION  
2. SOLID STATE THYRISTOR POWER CONTROLLERS.  
For best non-contact control of radiant heat, a Series #6  
Chromalox Thyristor Power Controller with manual poten-  
tiometer setting is recommended. Truly proportional output of  
from 0 — 100% can be easily dialed-in to suit the particular  
product or process requirements. The Series #6 panels are pre-  
engineered, pre-packaged assemblies in an enclosure with cir-  
cuit disconnect provided and ready for installation.  
FIRE/EXPOSION HAZARD. This heater is not  
intended for use in hazardous atmospheres where  
flammable vapors, gases, liquids or other com-  
bustible atmospheres are present as defined in the  
National Electrical Code.Failure to comply can  
result in personal injury or property damage.  
B. Maximum Ambient Temperatures  
Before energizing this heater:  
Chromalox Radiant Heaters are not recommended for applica-  
tions in ambient temperatures exceeding 450°F. Higher ambi-  
ent temperatures mean shorter heater life.  
1. Be sure all electrical connections are tightly made. Hold ter-  
minal with pliers when tightening screw.  
2. Be sure that all conductors are properly insulated.  
3. Be sure that all element assemblies have been properly  
replaced, and that secondary insulation bushings have not been  
omitted.  
Maximum work temperature in a given time depends on sever-  
al factors: Reflectivity of work, specific heat of work, mass of  
work, kW input and losses from oven, and time of exposure. As  
work temperature increases, the work loses heat by radiation  
and by convection to the surrounding ambient. Although it is a  
general principle of Radiant Heater application that work tem-  
perature conventionally exceeds ambient temperature, in cases  
where extremely high work temperatures are desired, it is nec-  
essary to enclose the heaters in order to increase the ambient.  
If evaporation of a liquid is desired as a result of increasing  
work temperature, it is necessary to provide ventilation air in  
order to carry away the evaporated liquid. Under carefully  
engineered circumstances, a maximum work temperature of  
600°F may be attained.  
A. Controlling Radiant Intensity  
Standard Radiant heaters are built to operate at 40 watts per sq.  
inch on the element sheath. When it is desired to reduce radiant  
intensity, one or more of the following methods may be used.  
1. INPUT CONTROLLERS. These motor-driven cycling  
devices can be used to vary heater output capacity from 4 to  
100%. They are usually connected in holding coil circuit of  
controlling magnetic contactors. See Chromalox Radiant  
Heater Manual for further information regarding Input  
Controllers and Contactors.  
MAINTENANCE  
C. Care of Reflectors  
Reflectors should be cleaned periodically. A mild soap and  
water solution or fine cleaning powder is best although more  
drastic means may be required if reflectors are badly soiled by  
chemical or other deposits. The reflector is aluminum. DO  
NOT use alkali cleaners since alkalies will dull reflector. Mild  
non-alkaline cleaners, such as used for scouring kitchen sinks,  
may be used. Reflectors are replaceable and may be purchased  
from Chromalox.  
ELECTRIC SHOCK HAZARD. Disconnect all power  
before installing or servicing heater. Failure to do  
so could result in personal injury or property dam-  
age. Heater must be installed or serviced by a  
qualified person in accordance with the National  
Electrical Code, NFPA 70.  
A. To Remove Heating Element  
D. Because of the high temperatures involved, periodically check  
and retighten heater terminal connections. This practice will  
help to avoid “hot terminals” and the resulting damage to wire  
insulation.  
E. Because of the fire hazards resulting from a process malfunc-  
tion, the related safety control used in the system should be  
periodically checked to ensure its proper operation.  
1. Remove terminal cover screws and terminal cover.  
2. Disconnect heating element from electrical leads at both ends.  
3. Remove screws from porcelain terminal blocks.  
4. Remove element support clips and secondary insulating bushings.  
5. Lift out elements.  
B. To Install Element  
Observe instructions for removing elements and proceed in  
reverse fashion. Be sure to replace secondary insulating bushings.  
-3-  
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RENEWAL PARTS IDENTIFICATION  
PARTS COMMON TO ALL HEATERS  
3
4
5
Terminal Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306-014405-001 (2)  
Terminal Cover Clip . . . . . . . . . . . . . . . . . . . . . . . . 056-014401-002 (2)  
End Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220-014462-001†  
220-014462-002  
8
Terminal Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . 248-046044-002 (4)  
MISCELLANEOUS HARDWARE AND PARTS  
9
Terminal Block (Bottom) . . . . . . . . . . . . . . . . . . . . 303-014317-001 (2)  
Hexnut #8-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200-049592-029 (2)  
Terminal Block (Top) . . . . . . . . . . . . . . . . . . . . . . . 303-014316-001 (2)  
Screw #8-32 x 2-1/4” long. . . . . . . . . . . . . . . . . . . 248-075512-390 (2)  
Screw #8-32 x 3/8” long . . . . . . . . . . . . . . . . . . . . 248-075519-080 (4)  
Screw #8-32 x 3/8” long . . . . . . . . . . . . . . . . . . . . 248-075512-053 (4)  
Saddle Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238-026539-001 (4)  
Jumper Strap  
10  
11  
12  
13  
14  
16  
17  
(furnished with RADD-7604X10 only) . . . . . . . . 166-075230-030 (2)  
HEATER MOUNTING CLAMP ASSEMBLY  
See Figures 1, 2, 3, and 4, page 1.  
For mounting heater with model numbers up to RADD 7000, use mounting  
clamp assembly part no. 168-013071-001. For mounting heaters above  
model number RADD 7000, use mounting clamp assembly part no. 168-  
013071-002.  
† Indicates stamped end plate with voltage, wattage, etc.  
NOTE: Part numbers suffixed by a number in ( ) indicates the quantity of the same part  
number used.  
19  
PARTS COMMON TO LONGER HEATERS  
(RADD-7604X13, RADD-7604X9A, and RADD-7724X38)  
18  
19  
20  
21  
22  
Conduit Support Bracket. . . . . . . . . . . . . . . . . . . . . . . . 059-036915-001 (5)  
#12 Gauge leadwire, 8”long . . . . . . . . . . . . . . . . . . . . . 175-048142-171 (2)  
4” Conduit Box, Octagonal . . . . . . . . . . . . . . . . . . . . . . 025-036918-001  
Conduit Box Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 080-013160-004  
1/2” 90° Angle Box Connector . . . . . . . . . . . . . . . . . . . 119-075455-002  
1/2” Box Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . 119-075454-005  
3/4 to 1/2” Reducing Washer . . . . . . . . . . . . . . . . . . . . 328-114681-001 (2)  
23  
26  
27  
Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-117271-001  
(includes terminal block and jumper straps)  
Model  
Number  
1/2” Flexible  
Steel Conduit  
#10 Gauge  
Leadwire  
24  
25  
RADD-7604X13  
RADD-7604X9A  
RADD-7724X38  
069-024328-011  
069-024328-010  
069-024328-012  
175-048141-078  
175-048141-077  
175-048141-079  
-4-  
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RENEWAL PARTS IDENTIFICATION  
Watts  
per  
Element  
Element  
Support  
Clip  
Bushing  
15 Retaining  
Clip  
1
2
3
6
7
Model  
Number  
Element  
Model Number  
Reflector  
Sheet  
Terminal  
Cover  
Insulation  
Bushing  
Volts  
120  
208  
240  
275  
RTU-2083A-120V (2)  
RTU-2083AV-208V (2)  
RTU-2083A-240V (2)  
RTU-2083AV-275V (2)  
RADD-2164  
800  
234-013411-011  
234-013411-012  
306-014405-001 (2)  
————————–  
————————– ————————–  
120  
208  
240  
275  
RTU-3113A-120V (2)  
RTU-3113AV-208V (2)  
RTU-3113A-240V (2)  
RTU-3113AV-275V (2)  
RADD-3224  
RADD-3264  
RADD-4364  
RADD-5434  
RADD-5504  
RADD-6544  
RADD-6604  
RADD-7674  
RADD-7724  
1100  
1300  
1800  
2150  
2500  
2700  
3000  
3350  
3600  
4500  
306-014405-001 (2)  
306-014405-001 (2)  
306-014405-001 (2)  
306-014405-001 (2)  
306-014405-001 (2)  
306-014405-001 (2)  
306-014405-001 (2)  
306-014405-001 (2)  
306-014405-001 (2)  
306-014405-001 (2)  
————————–  
————————–  
032-013454-001 (4)  
————————– ————————–  
————————– ————————–  
208  
240  
275  
480  
RTU-3133AV-208V (2)  
RTU-3133A-240V (2)  
RTU-3133AV-275V (2)  
RTU-3133A-480V (2)  
234-013411-013  
234-013411-013  
234-013411-013  
234-013411-013  
208  
240  
275  
480  
RTU-4183AV-208V (2)  
RTU-4183A-240V (2)  
RTU-4183AV-275V (2)  
RTU-4183A-480V (2)  
234-013411-014  
059-014304-002  
059-017175-001  
208  
240  
275  
480  
RTU-5213AV-208V (2)  
RTU-5213A-240V (2)  
RTU-5213AV-275V (2)  
RTU-5213A-480V (2)  
234-013411-015  
234-013411-015  
234-013411-015  
234-013411-015  
032-013454-001 (8)  
032-013454-001 (8)  
032-013454-001 (8)  
032-013454-001 (8)  
059-014304-002 (2)  
059-014304-002 (2)  
059-014304-002 (2)  
059-014304-002 (2)  
059-017175-001 (2)  
059-017175-001 (2)  
059-017175-001 (2)  
059-017175-001 (2)  
208  
240  
275  
480  
RTU-5253AV-208V (2)  
RTU-5253A-240V (2)  
RTU-5253AV-275V (2)  
RTU-5253A-480V (2)  
234-013411-016  
032-013454-001 (12)  
059-014304-002 (3)  
059-017175-001 (3)  
208  
240  
275  
480  
RTU-6273AV-208V (2)  
RTU-6273A-240V (2)  
RTU-6273AV-275V (2)  
RTU-6273A-480V (2)  
234-013411-017  
234-013411-017  
234-013411-017  
234-013411-017  
032-013454-001 (12)  
032-013454-001 (12)  
032-013454-001 (12)  
032-013454-001 (12)  
059-014304-002 (3)  
059-014304-002 (3)  
059-014304-002 (3)  
059-014304-002 (3)  
059-017175-001 (3)  
059-017175-001 (3)  
059-017175-001 (3)  
059-017175-001 (3)  
208  
240  
275  
480  
RTU-6303AV-208V (2)  
RTU-6303A-240V (2)  
RTU-6303AV-275V (2)  
RTU-6303A-480V (2)  
234-013411-018  
032-013454-001 (16)  
059-014304-002 (4)  
059-017175-001 (4)  
208  
240  
275  
480  
RTU-7333AV-208V (2)  
RTU-7333A-240V (2)  
RTU-7333AV-275V (2)  
RTU-7333A-480V (2)  
032-013454-001 (16)  
032-013454-001 (16)  
032-013454-001 (16)  
032-013454-001 (16)  
059-014304-002 (4)  
059-014304-002 (4)  
059-014304-002 (4)  
059-014304-002 (4)  
059-017175-001 (4)  
059-017175-001 (4)  
059-017175-001 (4)  
059-017175-001 (4)  
234-013411-006*  
and  
234-013411-015*  
208  
240  
275  
480  
RTU-7363AV-208V (2)  
RTU-7363A-240V (2)  
RTU-7363AV-275V (2)  
RTU-7363A-480V (2)  
234-013411-004*  
and  
234-013411-012*  
032-013454-001 (20)  
059-014304-002 (5)  
059-017175-001 (5)  
208  
240  
275  
480  
RTU-8453AV-208V (2)  
RTU-8453A-240V (2)  
RTU-8453AV-275V (2)  
RTU-8453A-480V (2)  
234-013411-049 (2)  
234-013411-049 (2)  
234-013411-049 (2)  
234-013411-049 (2)  
032-013454-001 (20)  
032-013454-001 (20)  
032-013454-001 (20)  
032-013454-001 (20)  
059-014304-002 (5)  
059-014304-002 (5)  
059-014304-002 (5)  
059-014304-002 (5)  
059-017175-001 (5)  
059-017175-001 (5)  
059-017175-001 (5)  
059-017175-001 (5)  
RADD-8904  
RADD-7604X10  
240  
4000 RTU-7303AX10-240V (2)  
5000 RTU-7303AX13-240 (2)**  
5500 RTU-7303AX9A-240 (2)**  
6500 RTU-7363AX38-240 (2)**  
234-013411-016 (2)  
243-013411-058 (3)  
234-013411-057 (4)  
234-013411-059 (4)  
306-014405-001 (2)  
306-014405-002 (2)  
306-036916-003 (2)  
306-036916-003 (2)  
023-013454-001 (24)  
032-013454-001 (23)  
032-013454-001 (32)  
032-013454-001 (32)  
059-014304-002 (8)  
059-014304-002 (8)  
059-014304-002 (8)  
059-014304-002 (8)  
059-017175-001 (6)  
059-017175-001 (9)  
059-017175-001 (10)  
059-017175-001 (11)  
RADD-7604X13 240 or 480  
RADD-7604X9A 240 or 480  
RADD-7724X38 240 or 480  
*For ease of installation, these reflectors shipped in two pieces (one each of part numbers listed).  
**Shipped as 480V. Convert to 240V by changing jumpers. See WIRING Section on page 2.  
NOTES:  
1. Part numbers suffixed by a number in ( ) indicates the quantity of the same part number used.  
2. Intelocking connector parts have been discontinued.  
-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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