Chromalox Electric Heater PG405 5 User Manual

®
Chromalox  
Installation, Operation  
SERVICE REFERENCE  
and  
DIVISION  
4
SECTION U-RAD  
SALES  
REFERENCE  
RENEWAL PARTS IDENTIFICATION  
(Supersedes PG405-4)  
PG405-5  
161-048457-001  
DATE  
APRIL, 2005  
Type U-RAD Electric Radiant Heaters  
Conduit  
Connector  
Single-Element U-RAD  
B
Double-Element U-RAD  
A
B
A
!
The Safety Alert Symbol  
risk of personal injury.  
is used to indicate a  
Length (In.)  
Model  
Volts  
kW  
Overall  
Heated  
Please familiarize yourself with these instructions before  
attempting to install or operate this Radiant Heater.  
Before Installing  
Two U-Shaped Elements  
U-RAD-22  
U-RAD-22V  
U-RAD-32  
U-RAD-32V  
U-RAD-33  
U-RAD-33V  
U-RAD-42V  
U-RAD-42  
U-RAD-43V  
U-RAD-43  
U-RAD-44V  
U-RAD-44  
U-RAD-52V  
U-RAD-52  
U-RAD-53V  
U-RAD-53  
U-RAD-54V  
U-RAD-54  
U-RAD-55V  
U-RAD-55  
U-RAD-62V  
U-RAD-62  
U-RAD-63V  
U-RAD-63  
U-RAD-64V  
U-RAD-64  
U-RAD-65V  
U-RAD-65  
U-RAD-66V  
U-RAD-66  
U-RAD-72V  
U-RAD-72  
U-RAD-73V  
U-RAD-73  
U-RAD-74V  
U-RAD-74  
U-RAD-75V  
U-RAD-75  
U-RAD-76V  
U-RAD-76  
U-RAD-77V  
U-RAD-77  
120 or 240  
1600  
1900  
2200  
2600  
2900  
3600  
3300  
3600  
4300  
5000  
3800  
4100  
4800  
5500  
6000  
4400  
4700  
5400  
6100  
6600  
7200  
25-1/2  
28-5/8  
31-3/4  
36-9/16  
39-11/16  
47-9/16  
44  
16-5/8  
19-3/4  
22-7/8  
27-11/16  
30-13/16  
38-11/16  
35-1/8  
38-1/4  
46-3/16  
53-9/16  
41-1/8  
44-1/4  
52-3/16  
59-5/8  
65-5/8  
47-1/4  
50-3/8  
58-1/4  
65-5/8  
71-3/4  
77-7/8  
208 or 275  
120 or 240  
208 or 275  
120 or 240  
208 or 275  
208 or 275  
240  
208 or 275  
240  
208 or 275  
240  
208 or 275  
240  
208 or 275  
240  
208 or 275  
240 or 480  
208 or 275  
240 or 480  
208 or 275  
240  
1. Open carton and remove heater at the place of installation.  
Mounting clamps are in parts bag in carton.  
2. Check nameplate volt and watt rating against your power supply  
voltage and heating requirements of your installation. This  
nameplate is located on one end of the heater.  
The system designer is responsible for the safety of  
this equipment and should install adequate back-up  
controls and safety devices with their electric heat-  
ing equipment. Where the consequences of failure  
could result in personal injury or property damage,  
back-up controls are essential.  
47-1/8  
55-1/16  
62-7/16  
50  
Specifications Table –  
Length (In.)  
208 or 275  
240  
53-1/8  
61-1/16  
68-1/2  
74-1/2  
56-1/8  
59-1/4  
67-1/8  
74-1/2  
80-5/8  
86-3/4  
208 or 275  
240 or 480  
208 or 275  
240 or 480  
208 or 275  
240 or 480  
208 or 275  
240  
Model  
Volts  
kW  
Overall  
Heated  
Single U-Shaped Element  
U-RAD-2  
U-RAD-2V  
U-RAD-3  
U-RAD-3V  
U-RAD-4V  
U-RAD-4  
U-RAD-5V  
U-RAD-5  
U-RAD-6V  
U-RAD-6  
U-RAD-7V  
U-RAD-7  
120 or 240  
800  
12-3/4  
15-7/8  
23-13/16  
31-1/4  
37-1/4  
43-3/8  
8-5/16  
11-7/16  
19-3/8  
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  
1100  
1800  
2500  
3000  
3600  
208 or 275  
240  
26-13/16  
32-13/16  
38-15/16  
208 or 275  
240 or 480  
208 or 275  
240 or 480  
208 or 275  
240 or 480  
208 or 275  
240 or 480  
© 2010 Chromalox, Inc.  
 
WIRING  
7. Hold terminal with pliers and tighten the terminal screw  
securely with a screwdriver.  
Note: Where circuit wiring is installed in locations of high  
ambient temperature, conductors should be insulated in accor-  
dance with requirements for temperature and voltage.  
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.  
Wrong  
Right  
Radiant  
Heaters  
L1  
L2  
ELECTRIC SHOCK HAZARD.  
Any installation  
L1  
L2  
involving electric heaters must be performed by a  
qualified person and must be effectively grounded  
in accordance with the National Electrical Code to  
eliminate shock hazard.  
Figure 6  
8. SERIES CONNECTION of Radiant Heaters of equal volt  
and watt rating is permitted in all line voltages up to 600 volts.  
In making such series connections it is necessary to observe the  
“right” (series-parallel) connection rather than the “wrong”  
(parallel-series) connection both shown in Figure 6. If heaters  
are connected according to the “wrong” illustration, failure of  
any one heater will cause progressive failure of other heaters  
still operating.  
1. Electrical connection to the type U-RAD Radiant Heater is  
made through the 7/8dia. opening in the end of the terminal cover of  
the element assembly. A 1/2flexible conduit connector is provided  
with each element assembly for this purpose.  
2. Wiring should be run in flexible or rigid metal conduit and must  
be installed in accordance with the requirements of the National  
Electrical Code and such other local requirements by a qualified per-  
son as defined in the NEC.  
3. Access to the element terminals is obtained by removing  
3 Conductors  
in 1 Conduit  
18  
16  
the mounting bolt and nut (see Figure 8, item and )and slid-  
ing the terminal end of the element assembly out of the housing.  
4. Wires supplying power to heating element terminals shall have  
insulation rated for 150°C minimum.  
Radiant  
Heaters  
A
B
C
D
E
F
L1  
L2  
L3  
3 Conductors  
in 1 Conduit  
High temperatures will oxidize copper. Use only  
nickel-plated copper wire for supplying power to  
heater. Do not use aluminum conductors.  
Figure 7  
5. A sufficient length of this wire (not less than 12) should be  
used to extend from each heater terminal into a connection box  
location where the temperature does not exceed 300˚F.  
6. Assemble terminal, screw and wire as shown in Fig. 5.  
9. DELTA CONNECTIONS — When heaters occur in multi-  
ples of three, they may be connected to, and balanced across,  
three-phase lines. The most commonly used connection is the  
delta connection illustrated in Figure 7.  
Three phase Delta connections to minimize inductive effect in  
conduits are made per this diagram. The rule: run all 3 three-  
phase conductors in the same conduit as far as possible. For sin-  
gle-phase, run only two conductors and follow the same rule.  
Figure 5  
 
OPERATION  
2. SOLID STATE THYRISTOR POWER CON-  
TROLLERS.  
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 circuit disconnect provided and ready for installation.  
B. Maximum Ambient Temperatures —  
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.  
Before energizing this heater:  
1. Be sure all electrical connections are tightly made. Hold ter-  
CHROMALOX Radiant Heaters are not recommended for  
applications in ambient temperature exceeding 450˚F. Higher  
ambient temperatures mean shorter heater life.  
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 gen-  
eral principle of Radiant Heater application that work tempera-  
ture 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 approximately  
40 watts per sq. inch on the element sheath. When it is desired  
to reduce radiant intensity, one or more of the following meth-  
ods 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  
magnetic contactors. See Chromalox Radiant Heater Manual  
for further information regarding Input Controllers and  
Contactors.  
MAINTENANCE  
B. To Install Element —  
Observe instructions for removing element and proceed in  
reverse fashion. Be sure to replace secondary insulating bushings.  
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 qual-  
ified person in accordance with the National  
Electrical Code, NFPA 70.  
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.  
A. To Remove Heating Element —  
18  
16  
1. Remove element assembly mounting nut and bolt  
and  
and  
element support clips (see Figure 8) and slide element assembly out  
of housing.  
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 element out of heater.  
 
RENEWAL PARTS IDENTIFICATION  
2
3
4
2
3
4
Aluminum  
Housing  
Aluminum  
Housing  
Model  
Volts  
kW  
Element  
Reflector  
Model  
Volts  
kW  
Element  
Reflector  
UTU-4-208V  
UTU-3-208V  
UTU-4-240V  
UTU-3-240V  
UTU-4-275V  
UTU-3-275V  
UTU-4(2)-208V  
UTU-4(2)-240V  
UTU-4(2)-275V  
UTU-5-208V  
UTU-2-208V  
UTU-5-240V  
UTU-2-240V  
UTU-5-275V  
UTU-2-275V  
UTU-5-208V  
UTU-3-208V  
UTU-5-240V  
UTU-3-240V  
UTU-5-275V  
UTU-3-275V  
UTU-5-208V  
UTU-4-208V  
UTU-5-240V  
UTU-4-240V  
UTU-5-275V  
UTU-4-275V  
UTU-5-480V  
UTU-4-480V  
UTU-5(2)-208V  
UTU-5(2)-240V  
UTU-5(2)-275V  
UTU-5(2)-480V  
UTU-6-208V  
UTU-2-208V  
UTU-6-240V  
UTU-2-240V  
UTU-6-275V  
UTU-2-275V  
UTU-6-208V  
UTU-3-208V  
UTU-6-240V  
UTU-3-240V  
UTU-6-275V  
UTU-3-275V  
UTU-6-208V  
UTU-4-208V  
UTU-6-240V  
UTU-4-240V  
UTU-6-275V  
UTU-4-275V  
UTU-6-480V  
UTU-4-480V  
234-016383-003  
234-016383-002  
234-016383-003  
234-016383-002  
234-016383-003  
234-016383-002  
UTU-6-208V  
UTU-5-208V  
UTU-6-240V  
UTU-5-240V  
UTU-6-275V  
UTU-5-275V  
UTU-6-480V  
UTU-5-480V  
UTU-6(2)-208V  
UTU-6(2)-240V  
UTU-6(2)-275V  
UTU-6(2)-480V  
UTU-7-208V  
UTU-2-208V  
UTU-7-240V  
UTU-2-240V  
UTU-7-275V  
UTU-2-275V  
UTU-7-208V  
UTU-3-208V  
UTU-7-240V  
UTU-3-240V  
UTU-7-275V  
UTU-3-275V  
UTU-7-208V  
UTU-4-208V  
UTU-7-240V  
UTU-4-240V  
UTU-7-275V  
UTU-4-275V  
UTU-7-480V  
UTU-4-480V  
UTU-7-208V  
UTU-5-208V  
UTU-7-240V  
UTU-5-240V  
UTU-7-275V  
UTU-5-275V  
UTU-7-480V  
UTU-5-480V  
UTU-7-208V  
UTU-6-208V  
UTU-7-240V  
UTU-6-240V  
UTU-7-275V  
UTU-6-275V  
UTU-7-480V  
UTU-6-480V  
UTU-7(2)-208V  
UTU-7(2)-240V  
UTU-7(2)-275V  
UTU-7(2)-480V  
234-016383-005  
234-016383-004  
234-016383-005  
234-016383-004  
234-016383-005  
234-016383-004  
234-016383-005  
234-016383-004  
234-016383-005 (2)  
234-016383-005 (2)  
234-016383-005 (2)  
234-016383-005 (2)  
234-016383-006  
234-016383-001  
234-016383-006  
234-016383-001  
234-016383-006  
234-016383-001  
234-016383-006  
234-016383-002  
234-016383-006  
234-016383-002  
234-016383-006  
234-016383-002  
234-016383-006  
234-016383-003  
234-016383-006  
234-016383-003  
234-016383-006  
234-016383-003  
234-016383-006  
234-016383-003  
234-016383-006  
234-016383-004  
234-016383-006  
234-016383-004  
234-016383-006  
234-016383-004  
234-016383-006  
234-016383-004  
234-016383-006  
234-016383-005  
234-016383-006  
234-016383-005  
234-016383-006  
234-016383-005  
234-016383-006  
234-016383-005  
234-016383-006 (2)  
234-016383-006 (2)  
234-016383-006 (2)  
234-016383-006 (2)  
208  
240  
275  
208  
240  
275  
480  
U-RAD-43  
2900  
152-016376-005  
U-RAD-65  
5500  
152-016376-014  
208  
240  
275  
U-RAD-44  
U-RAD-52  
3600  
3300  
234-016383-003 (2) 152-016376-006  
208  
240  
275  
480  
234-016383-004  
234-016383-001  
234-016383-004  
152-016376-007  
234-016383-001  
234-016383-004  
234-016383-001  
234-016383-004  
234-016383-002  
234-016383-004  
152-016376-008  
234-016383-002  
234-016383-004  
234-016383-002  
234-016383-004  
234-016383-003  
234-016383-004  
234-016383-003  
152-016376-009  
234-016383-004  
234-016383-003  
234-016383-004  
234-016383-003  
234-016383-004 (2)  
234-016383-004 (2)  
234-016383-004 (2)  
234-016383-004 (2)  
234-016383-005  
234-016383-001  
234-016383-005  
152-016376-011  
234-016383-001  
234-016383-005  
234-016383-001  
234-016383-005  
234-016383-002  
234-016383-005  
152-016376-012  
234-016383-002  
234-016383-005  
234-016383-002  
234-016383-005  
234-016383-003  
234-016383-005  
234-016383-003  
152-016376-013  
234-016383-005  
U-RAD-66  
U-RAD-72  
6000  
4400  
152-016376-015  
152-016376-016  
208  
240  
275  
208  
240  
275  
208  
240  
275  
480  
208  
240  
275  
208  
240  
275  
208  
240  
275  
480  
208  
240  
275  
480  
208  
240  
275  
480  
U-RAD-53  
U-RAD-54  
3600  
4300  
U-RAD-73  
U-RAD-74  
4700  
5400  
152-016376-017  
152-016376-018  
208  
240  
275  
480  
U-RAD-55  
U-RAD-62  
5000  
3800  
152-016376-010  
208  
240  
275  
208  
240  
275  
208  
240  
275  
480  
U-RAD-75  
6100  
152-016376-015  
U-RAD-63  
U-RAD-64  
5
4100  
4800  
U-RAD-76  
U-RAD-77  
6600  
7200  
152-016376-019  
152-016376-020  
208  
240  
275  
480  
234-016383-003  
234-016383-005  
234-016383-003  
STANDARD PARTS USED ON ALL HEATERS  
Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303-014316-001  
Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303-014317-001  
Terminal Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .080-016868-001  
Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .027-016372-001  
Spacer Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .032-075525-012  
1/2” Flexible Conduit Connector and Locknut . . . . . . . . . . . . . . . .119-075454-005  
200-075482-002  
13 Insulating Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .032-013454-001  
14  
6
7
Bushing Retaining Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .059-017175-001  
15 Mounting Clamp Parts Bag — For mounting heaters with overall length less than  
74-1/2”, use Parts Bag 168-013071-001. For heaters with 74-1/2” or larger over-  
all length, use Parts Bag 168-013071-002.  
8
9
MISCELLANEOUS HARDWARE  
10  
16  
17  
18  
19  
#8-32 Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200-075520-064  
#8-32 x 1-3/4” Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .248-075512-194  
#8-32 x 1” Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .248-075512-185  
#8 Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .328-075528-036  
11  
12  
Terminal Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .248-046044-002  
Element Support Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .059-014304-002  
Note: Part Numbers suffixed by a number in ( ) indicates the number of parts of the same part number used or supplied if more than one.  
 
RENEWAL PARTS IDENTIFICATION  
2
3
4
17  
Aluminum  
Housing  
Model  
Volts  
kW  
Element  
Reflector  
120  
208  
240  
275  
208  
240  
275  
480  
208  
240  
275  
480  
208  
240  
275  
480  
208  
240  
275  
480  
120  
208  
240  
275  
UTU-3-120V  
UTU-3-208V  
UTU-3-240V  
UTU-3-275V  
UTU-4-208V  
UTU-4-240V  
UTU-4-275V  
UTU-4-480V  
UTU-5-208V  
UTU-5-240V  
UTU-5-275V  
UTU-5-480V  
UTU-6-208V  
UTU-6-240V  
UTU-6-275V  
UTU-6-480V  
UTU-7-208V  
UTU-7-240V  
UTU-7-275V  
UTU-7-480V  
UTU-2(2)-120V  
UTU-2(2)-208V  
UTU-2(2)-240V  
UTU-2(2)-275V  
UTU-3-120V  
UTU-2-120V  
UTU-3-208V  
UTU-2-208V  
UTU-3-240V  
UTU-2-240V  
UTU-3-275V  
UTU-2-275V  
UTU-3(2)-120V  
UTU-3(2)-208V  
UTU-3(2)-240V  
UTU-3(2)-275V  
UTU-4-208V  
UTU-2-208V  
UTU-4-240V  
UTU-2-240V  
UTU-4-275V  
UTU-2-275V  
7
U-RAD-3  
1100  
234-016383-002  
234-016383-003  
234-016383-004  
234-016383-005  
234-016383-006  
152-016384-002  
152-016384-003  
152-016384-004  
152-016384-005  
152-016384-006  
19  
Element  
Support  
Clip  
U-RAD-4  
U-RAD-5  
U-RAD-6  
U-RAD-7  
U-RAD-22  
1800  
2500  
3000  
3600  
1600  
5
10  
Assembly  
6
12  
2
13  
11  
8
16  
3
14  
4
234-016383-001 (2) 152-016376-001  
234-016383-002  
234-016383-001  
234-016383-002  
234-016383-001  
152-016376-002  
234-016383-002  
234-016383-001  
234-016383-002  
234-016383-001  
18  
120  
208  
240  
275  
9
16  
U-RAD-32  
1900  
Element assembly includes all parts shown except items3  
and4  
1
For element assembly part number, add prefix “R” to Element part  
120  
208  
240  
275  
number  
Ex: R UTU-6-208V.  
2
U-RAD-33  
U-RAD-42  
2200  
2600  
234-016383-002 (2) 152-016376-003  
4
3
2
Aluminum  
Housing  
Model  
Volts  
kW  
Element  
Reflector  
234-016383-003  
234-016383-001  
234-016383-003  
152-016376-004  
234-016383-001  
234-016383-003  
234-016383-001  
208  
240  
275  
120  
208  
240  
275  
UTU-2-120V  
UTU-2-208V  
UTU-2-240V  
UTU-2-275V  
U-RAD-2  
800  
234-016383-001  
152-016384-001  
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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