Chromalox Electric Heater PG434 3 User Manual

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.  
 
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
 
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
 
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
 
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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