OPERATING INSTRUCTIONS
OSRAM
1/24/01
SYLVANIA
Process Heat
131 Portsmouth Ave. Exeter, NH 03833 USA Tel: 800-258-8290 Fax: 603-772-1072
2
Always have sufficient airflow through the heater before applying power. Otherwise element will overheat very
quickly, and burn out.
NOTE:
A thermocouple cannot detect temperatures if there is no flow – turn on flow before
applying power, even when a controller with a thermocouple is being used.
Use style ‘A’ inline heaters for absolute leak-proof applications (150 PSI). Style ‘B’ Inline heaters will have some
air leakage through the lead wires.
Use phase angle fired power controllers. On-off controllers may shorten heater life (or burnout element).
For closed-loop control, use exposed junction type “K” thermocouple within one inch of the heater exit.
For closed-loop control, use a temperature controller with a fast sampling period (500ms) and minimal overshoot.
Installation
Securely mount the heater.
FOR 3/8”, ½”, AND 1 ¼” HEATER ONLY (#038821, 038822, 038823, 038824, 038825, AND 038826):
There are two feedthroughs on the heater. Each feedthrough has three wires (marked 1, 2, or 3) coming out of it.
Connect one power lead to one heater electrical feedthrough (or one lead wire) and connect the other power
lead to the other electrical feedthrough. (or other lead wire).
Connect the ground wire to the green grounding nut on the heater body.
Connect the air source to the heater.
If a thermocouple is used, ensure that it is located within one inch from the heater exit.
FOR 2 ½” HEATER ONLY (#063007):
18,000 WATT - 240 VOLT - SINGLE PHASE OPERATION:
Each of the two heater feedthroughs has three wires (marked 1, 2, or 3) coming out of it.
Connect one side of power to all three leads that exit one feedthrough (1, 2, and 3 together).
Connect the other side of the power to all three leads that exit the second feedthrough (1, 2, and 3 together).
Make sure the heater is properly grounded. Note: Run single phase, 240 volts, the heater will draw 75 Amps.
Connect the air source to the heater.
If a thermocouple is used, ensure that it is located within one inch from the heater exit.
18,000 WATT - 240 VOLT - THREE PHASE OPERATION:
Each of the two heater feedthroughs have three wires (marked 1, 2, or 3) coming out of it.
Connect the elements in a standard delta configuration. (Connect one power lead to each of the following pairs:
1-2, 2-3, 3-1).
Make sure the heater is properly grounded.
Note: Run three phase, 240 volts, the heater will draw 44 Amps.
Connect the filtered air source to the heater.
If a thermocouple is used, ensure that it is located within one inch from the heater exit.
Start-up
Reference the PERFORMANCE CURVES section for operational parameters before attempting to operate
heater(s).
Turn on air supply and adjust to desired flow/pressure.
If using a closed loop system, turn on power to the temperature and power controller, then set the desired
temperature on the temperature controller. If using an open loop system, increase power to the heater through
the power controller until the desired temperature is attained.
Performance Curves
The attached performance curves show exit air temperatures at different airflows and voltages. Pressure readings
(longer dashed lines) are measured at the inlet to the heater with no entrance or exit restrictions. Solid lines indicate
safe, normal-life operating conditions. The shorter dash lines indicate marginal, shorter-life operating conditions
leading to premature burnout. With a known flow (or pressure) at the heater entrance, follow the flow (or pressure)
line across until it meets the desired temperature curve. Drop a line straight down to intersect the x-axis. This point,
along the “Heater volts – true RMS” axis, represents the voltage required to generate the desired exit air temperature
at the chosen flow rate (inlet pressure).
