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<strong>www</strong>.<strong>sylvaniaheaters</strong>.<strong>com</strong>
CONTENTS<br />
Products & Applications . . . . 1<br />
About Air Heaters . . . . . . . . . 2<br />
Air Heaters . . . . . . . . . . . 4-17<br />
Reference Data . . . . . . . . . 18
Aerospace:<br />
• Combustion/flow simulation<br />
Packaging:<br />
• High speed poly-coated<br />
paperboard sealing<br />
• High speed heat shrink<br />
installations<br />
• Forming<br />
• Curing adhesives<br />
• Sterilizing bottles or cartons<br />
Automotive<br />
• Hot air bonding of body<br />
panels<br />
• Curing adhesives<br />
• Vacuum forming<br />
• Simulation of engine exhaust<br />
• Fuel Cell testing<br />
Plastics/Rubber:<br />
• Salt removal from rubber<br />
extrusions<br />
• Bending and forming of<br />
plastics<br />
• De-flashing of molded parts<br />
Textiles:<br />
• Welding plastic or vinyl<br />
fabrics<br />
• Heat treating specialty<br />
fabrics<br />
Semiconductor and<br />
Electronics:<br />
• Air knife in wave solder<br />
machines<br />
• Soldering/desoldering<br />
PC boards, lead frames,<br />
capacitors<br />
• Wafer and PC board drying<br />
• Heat shrinking wire<br />
insulation<br />
• Preheating process gases<br />
Sterilization:<br />
• Pharmaceuticals<br />
• Medical/surgical hardware<br />
• Packaging materials<br />
Paper/Printing<br />
• Speed drying coated paper<br />
• Adhesive activation<br />
• Ink drying<br />
WARNING: OSRAM SYLVANIA Air/Inert Gas Heaters should be used to heat air or an inert gas only. Use with explosive<br />
gases or in an explosive ambient can result in an explosive event, possibly leading to a serious accident or injury.
With air temperatures controllable to 1400°F ±1°, SYLVANIA Air Heaters are your solution for many critical applications. Whether you<br />
are sealing, melting, drying, sterilizing, bonding, or soldering, SYLVANIA Air Heaters with our patented Serpentine coil give you the<br />
control, precision, and long life you need for greater productivity.<br />
1<br />
Max Max<br />
Product Features kW Air Temp Air Press Use with Page<br />
°F (°C) PSI (Bar) Blower?<br />
Series I, II, III<br />
Basic heater with quartz<br />
insulator tube. Ideal for<br />
“spot” heating applications.<br />
0.6 – 2.4<br />
1 phase<br />
1600 (871)<br />
7 (0.5)<br />
No<br />
4<br />
Hot Air Tool<br />
Compact size. Built in “K”<br />
thermocouple allows for<br />
precise ±1 degree control.<br />
1.5 – 3.5<br />
1 phase<br />
1400 (760)<br />
60 (4)<br />
No<br />
6<br />
Serpentine II, VI<br />
Triple-pass exchanger<br />
housing improves<br />
efficiency and safety.<br />
2.0 – 8.0<br />
1 phase<br />
1500 (815)<br />
25 (1.7)<br />
No<br />
8<br />
Threaded Inline<br />
Serpentine element in<br />
high-pressure pipe for<br />
critical processes.<br />
1.6 – 18.0<br />
1/3 phase<br />
1400 (760)<br />
150 (10)<br />
No<br />
10<br />
SureHeat® JET<br />
All-purpose heater with two<br />
built-in “K” thermocouples<br />
for precise control and<br />
overtemp protection.<br />
3.0 – 8.0<br />
1 phase<br />
1400 (760)<br />
60 (4)<br />
Yes<br />
12<br />
SureHeat® MAX<br />
All-purpose heater with two<br />
built-in “K” thermocouples<br />
for precise control and<br />
overtemp protection.<br />
6.0 – 36.0<br />
1/3 phase<br />
1400 (760)<br />
60 (4)<br />
Yes<br />
14<br />
Flanged Inline<br />
Heavy-duty flanged heater<br />
for high-pressure and flow<br />
applications. “K” thermocouples<br />
measure phase<br />
temperatures and provide<br />
overtemp protection.<br />
36.0–192.0<br />
3 phase<br />
1400 (760)<br />
150 (10)<br />
Yes<br />
16
2<br />
Selecting an Air Heater<br />
The energy (kW) requirement is calculated from the following<br />
formula:<br />
kW = SCFM x (Texit – Tinlet)<br />
2500<br />
SCFM = Air flow in Standard* Cubic Feet per Minute<br />
Tinlet = Inlet Air Temperature (°F) (typically 70°F)<br />
Texit = Desired Exit Air Temperature (°F)<br />
Example: Heating 10 SCFM from ambient temperature<br />
(70°F) to 800°F:<br />
kW = 10 SCFM x (800°F – 70°F) = 2.9 kW<br />
2500<br />
Conversion Formulas:<br />
(Liters per Minute)/28.3 = Cubic Feet per Minute<br />
°C = 5/9 (°F – 32)<br />
°F = 9/5°C + 32<br />
*Please refer below for an explanation of Standard flowrate<br />
Air Sources<br />
If used properly, heater life of<br />
5000 hours or greater can<br />
be expected. To ensure long<br />
heater life and safe operation,<br />
follow these guidelines.<br />
Also read and understand<br />
your heater Operating Manual<br />
before use. Failure to follow<br />
these guidelines can result in<br />
heater damage, failure, or<br />
personal injury.<br />
Air Sources<br />
In general, <strong>com</strong>pressed air,<br />
and air from regenerative<br />
blowers may be used to<br />
supply OSRAM SYLVANIA air<br />
heaters. Your air source should<br />
be clean and dry. Dirt, grease,<br />
oil, or oil vapors, or corrosive<br />
or reactive gases will damage<br />
an air heater. Also, use air or<br />
inert gas only. Do not use with<br />
volatile or <strong>com</strong>bustible gases.<br />
pressure air for your air heating<br />
system. Blower size is based<br />
on the maximum amount of<br />
airflow (CFM or LPM) it can<br />
produce without any inlet or<br />
exit restrictions. When a heater<br />
or other restriction is attached<br />
to a blower, the maximum flow<br />
decreases. If the blower is<br />
severely restricted, the blower<br />
motor can overheat and fail.<br />
When designing your heating<br />
system, you should try to<br />
minimize air restrictions, and<br />
select a blower sufficient to<br />
over<strong>com</strong>e the backpressure<br />
generated by the heater,<br />
flare, and associated piping.<br />
Because of their small size,<br />
the Series, Hot Air Tool, and<br />
Serpentine II heaters should<br />
not be used with regenerative<br />
blowers.<br />
Compressed Air<br />
Compressed air is <strong>com</strong>monly<br />
available in most factories. It<br />
is high-pressure regulated air<br />
(typically to 100psi), and often<br />
contains oil for lubricating<br />
pneumatic valves and equipment.<br />
You must filter this oil to<br />
prevent fouling and damage to<br />
OSRAM SYLVANIA’s<br />
electric air heater elements.<br />
When measuring <strong>com</strong>pressed<br />
air flow rates, be sure you<br />
are measuring Standard CFM<br />
or Standard LPM units. The<br />
“Standard” means that the<br />
units are measured at<br />
standard temperature and<br />
pressure. Many flow meters<br />
are labeled SCFM, but this is<br />
incorrect at the higher<br />
pressures produced by<br />
<strong>com</strong>pressed air. For accurate<br />
flow measurements, you must<br />
consult your flow meter<br />
manual for converting CFM<br />
to “Standard” CFM. In the<br />
diagram below, the flow meter<br />
reading (CFM) is converted<br />
to SCFM using a Dwyer balltype<br />
flow meter conversion.<br />
Regenerative Blowers<br />
Regenerative blowers are<br />
<strong>com</strong>pact and inexpensive<br />
clean air sources. They can<br />
provide large amounts of low-
For detailed<br />
operating instructions,<br />
visit <strong>www</strong>.<strong>sylvaniaheaters</strong>.<strong>com</strong><br />
Controls<br />
A good control system is<br />
critical for long heater life.<br />
Before turning your control system<br />
on, you must have<br />
sufficient airflow through the<br />
heater before applying power.<br />
(Applies to heaters without<br />
SureHeat or Hot Air System<br />
over-temperature protection.)<br />
Only qualified individuals should<br />
install OSRAM SYLVANIA heaters<br />
and controls. Follow all<br />
applicable electrical codes and<br />
use proper wiring.<br />
Open-Loop (Manual) Control<br />
This simple method of control<br />
uses a manually operated<br />
power controller to apply a<br />
fixed voltage to the heating<br />
element. Using this system,<br />
the operator manually adjusts<br />
the controller to change heater<br />
temperature. Note that if the<br />
airflow is suddenly interrupted,<br />
the element could fail. The<br />
open-loop controller is generally<br />
used with OSRAM SYLVANIA’s<br />
Series heaters.<br />
Closed-Loop (Feedback)<br />
Control<br />
A closed-loop heater control<br />
system uses a power controller,<br />
temperature controller, and<br />
thermocouple to provide a<br />
constant output temperature,<br />
regardless of changes in airflow.<br />
The temperature controller<br />
also provides a convenient<br />
display of your process air<br />
temperature.<br />
Power Controller<br />
Phase angle fired SCR (Silicon<br />
Controlled Rectifier) power controls<br />
will provide the smoothest<br />
power regulation for OSRAM<br />
SYLVANIA Air Heaters.<br />
Other power controls may be<br />
suitable, such as distributive<br />
zero cross SSR (Solid State<br />
Relays) or other fast-switching<br />
SSR’s, but you should contact<br />
OSRAM SYLVANIA for approval<br />
before use.<br />
Temperature Controller<br />
Use only digital temperature<br />
controls with type-K thermocouple<br />
inputs. The temperature<br />
control output must match the<br />
input of the power control. (i.e.<br />
4-20mA, or 0-10VDC).<br />
A standard PID-type control<br />
with a wide proportional band<br />
setting will work best to minimize<br />
temperature overshoot.<br />
PID parameters may be<br />
auto-tuned, but only at temperatures<br />
well below the<br />
maximum of the heater. If the<br />
temperature rises too high<br />
during auto-tune, turn power<br />
off immediately.<br />
When using a Solid State Relay<br />
power control, the temperature<br />
controller cycle time should be<br />
set for 100ms or less.<br />
Thermocouple<br />
Use only a fine-wire (.030”<br />
max wire dia.), exposedjunction,<br />
type-K thermocouple<br />
placed within 1” of the heater<br />
exit for accurate temperature<br />
readings. Other thermocouple<br />
styles, or varying the distance<br />
from the heater exit will result<br />
in temperature measurement<br />
errors and/or heater failure.<br />
3
4<br />
Specifications<br />
• Air temperatures to 1600˚F<br />
(871˚C)<br />
• Quartz outer tube housing.<br />
• Nozzled (Style B) or openended<br />
(Style A) design<br />
• High-temperature silicone<br />
rubber Rear Adapter/<br />
Terminal Assembly<br />
• Maximum air pressure 7 PSI<br />
(0.5 bar)<br />
• Maximum inlet temperature<br />
120˚F (49˚C)<br />
• CE <strong>com</strong>pliant<br />
Performance<br />
1600<br />
Series Heaters<br />
Air Flow in SLPM<br />
0 11.75 23.5 47 94 142 189 236 283<br />
871<br />
1400<br />
760<br />
Air Temperature ˚F<br />
1200<br />
1000<br />
800<br />
649<br />
538<br />
427<br />
Air Temperature ˚C<br />
600<br />
400<br />
Series I<br />
Series II<br />
Series III<br />
316<br />
204<br />
0<br />
0 25 50 100 200 300 400 500 600<br />
Air Flow in SCFH<br />
0
Installation<br />
For detailed<br />
operating instructions,<br />
visit <strong>www</strong>.<strong>sylvaniaheaters</strong>.<strong>com</strong><br />
Mtg. Screw<br />
No. 3-48<br />
Clamp<br />
Adapter for nylon pressure tubing<br />
1.37"<br />
(34mm)<br />
Style A Tube<br />
Nut<br />
Lockwasher<br />
Terminal<br />
5<br />
OD "B"<br />
"A"<br />
Style B Tube<br />
1.00" (25.4mm)<br />
"A"<br />
ID "C"<br />
Products<br />
Part Number Tube Style Max. Watts Max. Volts Tube Length Tube O.D. Nozzle I.D. (Style B)<br />
“A” “B” “C”<br />
Series I<br />
010226 A 1050 180 6.88" .41" —<br />
(175mm) (10mm) —<br />
014372 A 1000 130 7.75" .41" —<br />
(197mm) (10mm) —<br />
014682 B 680 145 7.88" .41" .07"<br />
(200mm) (10mm) (2mm)<br />
014683 B 650 105 8.75" .41" .07"<br />
(222mm) (10mm) (2mm)<br />
Series II<br />
016501 A 1125 130 3.88" .41" —<br />
(98mm) (10mm) —<br />
016503 A 850 80 3.88" .41" —<br />
(98mm) (10mm) —<br />
016502 B 600 95 4.88" .41" .07"<br />
(124mm) (10.4mm) (2mm)<br />
016504 B 650 70 4.88" .41" .07"<br />
(124mm) (10mm) (2mm)<br />
Series III<br />
017558 A 2050 160 6.88" .59" —<br />
(175mm) (15mm) —<br />
017575 B 1450 135 7.88" .59" .12"<br />
(200mm) ( 15mm) (3mm)<br />
Accessories<br />
Part Number<br />
Description<br />
057081 Open Loop (Manual) power controller 25A<br />
Outer Shields — Open End<br />
015509 For Series I 014372<br />
017853 For Series II<br />
Outer Shields — Flared<br />
037261 For Series I 010226, 014682
6<br />
Specifications<br />
• Air temperatures controllable<br />
to 1400˚F (760˚C)<br />
• Built-in “K” type thermocouple<br />
• 1/4” hose barb air<br />
connection<br />
• Maximum inlet temperature<br />
120˚F (49˚C)<br />
• Maximum air pressure<br />
60 PSI (4Bar)<br />
• Slotted exit for flare<br />
attachment<br />
• 304 Stainless Steel body<br />
• 3’ (914mm) power and<br />
thermocouple leads<br />
• CE <strong>com</strong>pliant<br />
Performance<br />
Air Flow in SLPM<br />
0<br />
1500<br />
200 400 600<br />
1300<br />
Hot Air Tools<br />
1500W / 120V<br />
2000W / 240V<br />
3500W / 240V<br />
800<br />
650<br />
Temperature ˚F<br />
1100<br />
900<br />
500<br />
Temperature ˚C<br />
700<br />
350<br />
500<br />
0 500 1000 1500<br />
Air Flow in SCFH
Installation<br />
For detailed<br />
operating instructions,<br />
visit <strong>www</strong>.<strong>sylvaniaheaters</strong>.<strong>com</strong><br />
.81" (20.6mm) Dia.<br />
8.88" (225.6mm)<br />
Hose Barb<br />
7<br />
.74" (18.8mm)<br />
ID<br />
.62" (15.8mm)<br />
Electrical & TC Leads<br />
.88" (22.4mm)<br />
Dia.<br />
Products<br />
Part Max. Max. Max. Min.<br />
Number Watts Volts Amps Flow<br />
SCFH (SLPM)<br />
068462 1500W 120 13 30 (14)<br />
068463 2000W 240 9 70 (33)<br />
068464 3500W 240 15 90 (43)<br />
Accessories<br />
Part Number<br />
Description<br />
068472 Flare (includes clamp)<br />
.06" x 2.5" (1.52mm x 63.5mm) opening<br />
057081 Open Loop (manual) Power Control, 25A, 240V, 1<br />
066823 Closed Loop Power Control, 30A, 240V, 4–20mA (used with 070429)<br />
070429 Digital Temperature Control, 1/16 DIN (used with 066823), 4–20mA<br />
.06"x 2.5" Opening<br />
(1.52mm x 63.5mm)<br />
FLARE<br />
2.19"<br />
(55.6mm)
8<br />
Specifications<br />
• Air temperatures controllable<br />
to 1500˚F (815˚C)<br />
• Serpentine II to 3.6kW<br />
• Serpentine VI to 8.0kW<br />
• Triple Pass Heat Exchanger<br />
uses in<strong>com</strong>ing air to cool<br />
outer shell<br />
• Maximum air pressure<br />
25 PSI (1.7 bar)<br />
• Replaceable element<br />
assemblies<br />
• CE <strong>com</strong>pliant<br />
Performance<br />
1600<br />
1400<br />
1200<br />
Serpentine II Maximum Performance<br />
Air Flow in SLPM<br />
0 94 189 283 378 472 566<br />
871<br />
760<br />
649<br />
Temperature ˚F<br />
1000<br />
800<br />
600<br />
400<br />
200<br />
2 kW<br />
2.8 kW<br />
3.6 kW<br />
3.6 kW (Two-stage)<br />
538<br />
427<br />
316<br />
204<br />
93.4<br />
Temperature ˚C<br />
0<br />
0 200 400 600 800 1000 1200<br />
Air Flow in SCFH<br />
0<br />
1600<br />
1400<br />
1200<br />
Serpentine VI Maximum Performance<br />
Air Flow in SLPM<br />
0 94 189 283 378 472 566 661 755 850 944 1045 1133<br />
871<br />
760<br />
649<br />
Temperature ˚F<br />
1000<br />
800<br />
600<br />
400<br />
200<br />
5 kW<br />
6 kW<br />
6 kW (Two-stage)<br />
8 kW<br />
538<br />
427<br />
316<br />
204<br />
93.4<br />
Temperature ˚C<br />
0<br />
0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400<br />
Air Flow in SCFH<br />
0
Installation<br />
Element<br />
Housing Assembly<br />
For detailed<br />
operating instructions,<br />
visit <strong>www</strong>.<strong>sylvaniaheaters</strong>.<strong>com</strong><br />
“D” Dia.<br />
“A”<br />
“A” Dia.<br />
“B”<br />
“E” NPT<br />
Air Inlet<br />
“B”<br />
“C”<br />
Products<br />
12" (304.8mm)<br />
Leads<br />
9<br />
Serpentine II Elements used with housing 029763<br />
Part Max. Max. Max. Length “A” O.D. “B”<br />
Number Watts Volts Amps<br />
029765 2kW 240 8.3 8.20" (208mm) 0.63" (16mm)<br />
029766 2.8kW 240 11.7 8.20" (208mm) 0.63" (16mm)<br />
029767 3.6kW 240 15 8.20" (208mm) 0.63" (16mm)<br />
060418 3.6kW (Two-stage) 240 15 8.63" (219mm) 0.63" (16mm)<br />
Serpentine VI Elements used with housing 057088<br />
Part Max. Max. Max. Length “A” O.D. “B”<br />
Number Watts Volts Amps<br />
040291 5kW 240 20.8 10.88" (276mm) 1.25" (32mm)<br />
040292 6kW 240 25 10.88" (276mm) 1.25" (32mm)<br />
061429 6kW (Two-stage) 240 25 10.88" (276mm) 1.25" (32mm)<br />
056548 8kW 240 33.3 10.88" (276mm) 1.25" (32mm)<br />
Housing Assemblies<br />
Part Serpentine “A” “B” “C” “D” “E”<br />
Number Type<br />
029763 ll 1.6" 9.0" 10.0" 0.7" 3/8" NPT<br />
(40mm) (229mm) (254mm) (18mm)<br />
057088 Vl 2.1" 11.9" 12.9" 1.4" 3/4" NPT<br />
(54mm) (302mm) (327mm) (35mm)<br />
Accessories<br />
Part Number<br />
Description<br />
039739 Serp II base adaptor assembly<br />
042339 Serp VI base adaptor assembly<br />
029485 Serp II TC holder (includes TC)<br />
040299 Serp VI TC holder (includes TC)<br />
039272 “K” type thermocouple probe, 3/16" (4.8mm) O.D.<br />
066823 Closed loop power control, 240V, 30A, 4–20mA<br />
057081 Open loop (manual) power control, 240V, 25A<br />
070429 Digital temperature controller, 1/16 DIN, 4–20mA
10<br />
Specifications<br />
• Air temperatures to 1400˚F<br />
(760˚C)<br />
• For applications requiring<br />
high pressure air<br />
• Both ends threaded 3/8",<br />
1/2", 1-1/4", and 2-1/2" NPT<br />
• 304 Stainless Steel housing<br />
• CE <strong>com</strong>pliant<br />
Style A<br />
• Should be used whenever<br />
an absolute leak-proof<br />
system (up to 150 PSI) is<br />
required<br />
• Two high temperature power<br />
feedthroughs<br />
• Maximum inlet temperature<br />
900˚F (482˚C)<br />
Style B<br />
• Maximum air pressure 150<br />
PSI, but will have slight air<br />
leakage through power wire<br />
strands<br />
• 12" (305mm) flexible power<br />
wires<br />
• Maximum inlet temperatures<br />
200°F (93˚C)<br />
Performance<br />
1600<br />
1400<br />
1200<br />
Inline Heaters Maximum Performance<br />
Air Flow in SLPM<br />
0 94 189 283 378 472 566 661 755 850 944 1045 1133 1416 1888 2360 2832 3304 3776<br />
871<br />
760<br />
649<br />
Temperature ˚F<br />
1000<br />
800<br />
600<br />
400<br />
200<br />
0<br />
316<br />
1.6 kW<br />
4.0 kW<br />
204<br />
6.0 kW<br />
18.0 kW<br />
93.4<br />
0<br />
0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 3000 4000 5000 6000 7000 8000<br />
Air Flow in SCFH<br />
538<br />
427<br />
Temperature ˚C
Installation<br />
For detailed<br />
operating instructions,<br />
visit <strong>www</strong>.<strong>sylvaniaheaters</strong>.<strong>com</strong><br />
3/8" THREADED INLINES<br />
.375" NPT<br />
Male<br />
STYLE A<br />
0.7" (17mm)<br />
.87" Dia.<br />
(22mm)<br />
#10–32<br />
2-Places<br />
10.75"<br />
(273mm)<br />
1.0"<br />
(25mm)<br />
.375" NPT<br />
Female<br />
4.3"<br />
(109mm)<br />
3/8 NPT<br />
Male<br />
STYLE B<br />
.95"<br />
(24mm)<br />
3/8 NPT<br />
Male<br />
0.7" (17mm)<br />
10.6"<br />
(270mm)<br />
(2) #16 AWG<br />
Wire 12" Long<br />
(305mm)<br />
1.3"<br />
(33mm)<br />
0.95" Dia.<br />
(24mm)<br />
3/8 NPT<br />
Female<br />
11<br />
1/2" THREADED INLINES<br />
.5" NPT<br />
Male<br />
STYLE A<br />
#10–32<br />
2-Places<br />
.5" NPT<br />
Male<br />
4.3"<br />
(109mm)<br />
.5" NPT<br />
Male<br />
1.13"<br />
(29mm)<br />
.5" NPT<br />
Male<br />
STYLE B<br />
(2) #14 AWG<br />
Wire 12" Long<br />
(305mm)<br />
2.0"<br />
(51mm)<br />
1.2" Dia.<br />
(30mm)<br />
0.84" (21mm)<br />
0.84" (21mm)<br />
9.0"<br />
(229mm)<br />
1.0"<br />
(25mm)<br />
9.5"<br />
(241mm)<br />
.5" NPT<br />
Female<br />
1-1/4" THREADED INLINES<br />
1.7"<br />
(43mm)<br />
1.25" NPT<br />
#10–32<br />
Male<br />
2-Places<br />
STYLE A<br />
1.25" NPT<br />
Male<br />
5.0"<br />
(127mm)<br />
1.7"<br />
(43mm)<br />
1.25" NPT<br />
Male<br />
STYLE B<br />
1.8"<br />
(46mm)<br />
.5" NPT<br />
Male<br />
#10 AWG<br />
Wire 12" Long<br />
(305mm)<br />
1.2"<br />
(30mm)<br />
2.0"<br />
(51mm)<br />
11.3"<br />
(287mm)<br />
1.0"<br />
(25mm)<br />
12.2"<br />
(310mm)<br />
1.25" NPT<br />
Female<br />
2-1/2" THREADED INLINE<br />
STYLE B<br />
60˚<br />
(typ)<br />
2.1"<br />
(54mm)<br />
STYLE B<br />
12.2"<br />
(310mm)<br />
Products<br />
Heater Size (NPT) Max. Watts Max. Volts Max. Amps Part No., Style A Part No., Style B<br />
3/8" 1.6kW 170 9.4 038821 038822<br />
1/2" 4.0kW 220 18.2 038823 038824<br />
1-1/4" 6.0kW 220 27.3 038825 038826<br />
2-1/2" 18.0kW 240 75.0 (1 ) /44.0 (3 ) N/A 063007<br />
Accessories<br />
Part Number<br />
Description<br />
057081 Open loop (manual) power control, 240V, 25A<br />
066823 Closed loop power control, 240V, 30A<br />
070429 Temperature controller — 1 ⁄16 DIN, 4–20mA<br />
039272 “K” Type Thermocouple Probe
12<br />
Specifications<br />
• Air temp controllable to 1400°F (760°C) ±1°<br />
• Power 3.0kW - 8.0kW 240V~ 1<br />
• Two internal “K” TC sensors for control and safety:<br />
o S1 measures inlet temp.<br />
o S2 measures exit temp.<br />
• Rapid heat-up and cool-down.<br />
• Maximum air pressure 60 PSI (4 Bar)<br />
• CE, UL <strong>com</strong>pliant<br />
• ‘Ceramic-only’ design for food<br />
packaging applications.<br />
• Max inlet temp 200°F (93°C)<br />
• Use SureHeat JET CONTROL<br />
(purchased separately) for easy installation.<br />
Performance
Installation<br />
For detailed<br />
operating instructions,<br />
visit <strong>www</strong>.<strong>sylvaniaheaters</strong>.<strong>com</strong><br />
Wiring Notes:<br />
• S1 and S2 sensors are “K” type thermocouples.<br />
• S1 measures inlet air temperature.<br />
• S2 measures exit air temperature.<br />
• See Operating Manual for control settings.<br />
13<br />
Products<br />
Part Number Description Max Watts Max Volts Max Amps<br />
074718 SureHeat JET 3.0kW Heater 3.0kW 240V~ 1 50/60 Hz 12.5<br />
074719 SureHeat JET 8.0kW Heater 8.0kW 240V~ 1 50/60 Hz 33.3<br />
Accessories<br />
Part Number Description Max Watts Max Volts Max Amps<br />
074722 SureHeat JET CONTROL 8.0kW 240V~ 1 50/60 Hz 35
14<br />
Specifications<br />
• Air temp controllable to 1400°F (760°C) ±1°<br />
• Power 6.0kW - 36.0kW 240/380/480V~ 1 /3<br />
• Two internal “K” TC sensors for control and safety:<br />
o S1 measures inlet temp.<br />
o S2 measures exit temp.<br />
• Rapid heat-up and cool-down.<br />
• Maximum air pressure 60 PSI (4 Bar)<br />
• CE, UL <strong>com</strong>pliant<br />
• ‘Ceramic-only’ design for food<br />
packaging applications.<br />
• Max inlet air temp 200°F (93°C)<br />
Performance
Installation<br />
For detailed<br />
operating instructions,<br />
visit <strong>www</strong>.<strong>sylvaniaheaters</strong>.<strong>com</strong><br />
Wiring Notes:<br />
• S1 and S2 sensors are "K" type thermocouples.<br />
• S1 measures inlet air temperature.<br />
• S2 measures exit air temperature.<br />
• See Operating Manual for control settings.<br />
Installation Notes:<br />
• 18kW, 36kW heater is 16" (406.4mm) long.<br />
• 6kW, 10k W heater is 12" (304.8mm) long.<br />
• Difference is 4" (101.6mm) shorter nozzle tube.<br />
15<br />
Products<br />
Part Number Description Max Max Volts Max<br />
Watts<br />
Amps<br />
074723 SureHeat MAX 6.0kW Heater 6.0kW 240V~ 1 50/60 Hz 25.0<br />
074724 SureHeat MAX 6.0kW Heater 6.0kW 240V~ 3 50/60 Hz 14.5<br />
074725 SureHeat MAX 6.0kW Heater 6.0kW 380V~ 3 50/60 Hz 9.1<br />
074726 SureHeat MAX 6.0kW Heater 6.0kW 480V~ 3 50/60 Hz 7.2<br />
074727 SureHeat MAX 10.0kW Heater 10.0kW 240V~ 1 50/60 Hz 41.7<br />
074728 SureHeat MAX 10.0kW Heater 10.0kW 240V~ 3 50/60 Hz 24.1<br />
074729 SureHeat MAX 10.0kW Heater 10.0kW 380V~ 3 50/60 Hz 15.2<br />
074731 SureHeat MAX 10.0kW Heater 10.0kW 480V~ 3 50/60 Hz 12.0<br />
074732 SureHeat MAX 18.0kW Heater 18.0kW 240V~ 3 50/60 Hz 43.4<br />
074733 SureHeat MAX 18.0kW Heater 18.0kW 380V~ 3 50/60 Hz 27.4<br />
074734 SureHeat MAX 18.0kW Heater 18.0kW 480V~ 3 50/60 Hz 21.7<br />
074735 SureHeat MAX 30.0kW Heater 30.0kW 380V~ 3 50/60 Hz 45.6<br />
074736 SureHeat MAX 36.0kW Heater 36.0kW 480V~ 3 50/60 Hz 43.4<br />
Accessories<br />
Part Number<br />
Description<br />
074829 1/16 DIN Digital temperature control (for S2)<br />
074835 Thermal safety switch (for S1)
16<br />
Specifications<br />
• Designed for high pressure, high<br />
flow applications<br />
• Air/inert gas temperatures to<br />
1400˚F (760˚C)<br />
• Uses SureHeat overtemperature<br />
protection system<br />
• Up to 192kW in a <strong>com</strong>pact 2'<br />
(610mm) long size<br />
• Maximum air pressure<br />
150 PSI (10 Bar)<br />
• 304 Stainless Steel<br />
ASME welded 300 lb. flanged<br />
housing<br />
• Maximum inlet temperature 900˚F<br />
(482˚C)<br />
• Built-in “K” type<br />
thermocouple<br />
Performance<br />
Flanged Inline Heater Maximum Performance<br />
1600<br />
871<br />
1400<br />
1200<br />
36 kW<br />
72 kW<br />
144 kW<br />
192 kW<br />
760<br />
649<br />
Exit Air Temperature ˚F<br />
1000<br />
800<br />
600<br />
400<br />
538<br />
427<br />
316<br />
204<br />
Temperature ˚C<br />
200<br />
93.4<br />
0<br />
0 200 400 600 800 1000<br />
Air Flow in SCFM
Installation<br />
For detailed<br />
operating instructions,<br />
visit <strong>www</strong>.<strong>sylvaniaheaters</strong>.<strong>com</strong><br />
17<br />
Products<br />
Heater Part Max. Max. Max. Pipe I.D. Flange O.D. Bolt Circle Replacement SCR<br />
Number* kW Volts Amps “I” “D” “C” Element Power Control<br />
# Holes/Dia. Part Number Part Number<br />
073166 36.0 480 - 3Ø 45 4.0" (102mm) 10.0" (254mm) 8-.088”/7.88” 073167 072765<br />
073377 72.0 480 - 3Ø 87 6.0" (152mm) 12.5" (318mm) 12-.088”/10.62” 073378 072764<br />
073384 144.0 480 - 3Ø 175 8.0" (203mm) 15.0" (381mm) 12-1.00”/13.00” 073385 072763<br />
073153 192.0 480 - 3Ø 235 8.0" (203mm) 15.0" (381mm) 12-1.00”/13.00” 073253 072762<br />
*includes element<br />
A <strong>com</strong>plete functional system must have heater, SCR power control, over-temperature board, and digital temperature control.<br />
Accessories<br />
Part Number<br />
Description<br />
070429 1/16 DIN digital temperature control, 4–20 mA<br />
073262 Over-temperature control board (required)<br />
039272 Replacement “K” type thermocouple probe
18 A. Air Heater Energy Requirement<br />
D. Single Phase Wiring<br />
kW = SCFM x (Texit – Tinlet) / 2500<br />
B. Temperature Conversions<br />
°F = 9/5 (°C) + 32<br />
°C = 5/9 (°F – 32)<br />
C. Air Flow Conversions<br />
SCFM = SCFH / 60 = SLPM / 28.3<br />
SLPM = SCFH / 2.12<br />
SCMH = SCFH / 35.3<br />
SCFM = (Pounds of Air Per Minute) / (.080 lbs/ft3)<br />
SCFM<br />
SCFH<br />
SLPM<br />
SCMH<br />
= Standard Cubic Feet per Minute<br />
= Standard Cubic Feet per Hour<br />
= Standard Liters per Minute<br />
= Standard Cubic Meters per Hour<br />
V = I x R (Volts = Amps x Ohms)<br />
I = W / V (Amps = Watts / Volts)<br />
W = V 2 /R (Watts = (Volts x Volts) / Ohms)<br />
E. Three Phase Wiring<br />
Delta Configuration<br />
R = R 1 = R 2 = R 3<br />
2<br />
Wdelta = 3(V L )/R<br />
Wdelta = 1.73 x V L x I L<br />
IP = I L /1.73<br />
VP = V L<br />
Wye Configuration<br />
R = R 1 = R 2 = R 3<br />
2<br />
Wwye = (V L )/R = 3(V P 2 )/R<br />
Wwye = 1.73 x V L x I P<br />
IP = I L<br />
VP = V L /1.73<br />
Wye Configuration<br />
Delta Configuration
For orders and product information:<br />
OSRAM SYLVANIA<br />
131 Portsmouth Avenue<br />
Exeter, NH 03833 USA<br />
Tel. 800-258-8290<br />
In NH 603-772-4331<br />
Fax 603-772-1072<br />
<strong>www</strong>.<strong>sylvaniaheaters</strong>.<strong>com</strong><br />
OSRAM SYLVANIA<br />
HEADQUARTERS<br />
100 Endicott Street<br />
Danvers, MA 01923<br />
(978) 777-1900<br />
<strong>www</strong>.sylvania.<strong>com</strong><br />
© 2005 OSRAM SYLVANIA<br />
PMC 007<br />
The information and re<strong>com</strong>mendations contained in<br />
this publication are based upon data collected by<br />
OSRAM SYLVANIA and believed to be correct. However,<br />
no guarantee or warranty of any kind, expressed or implied,<br />
is made with respect to the information contained herein,<br />
and OSRAM SYLVANIA assumes no responsibility for the<br />
results of the use of products and processes described<br />
herein. No statements or re<strong>com</strong>mendations made herein<br />
are to be construed as inducements to infringe any relevant<br />
patent, now or hereafter in existence.