Chromalox SDRA Installation & Operation Manual

Installation, Operation and Portable Industrial Unit Blower Air Heater Types SDRA and SDRA-RG © 2010 Chromalox, Inc. Specifications – Table 1 GENERAL IMPORTANT: SAVE THESE INSTRUCTIONS RISK OF FIRE. Do not use as a residential or house- hold heater Hazard of Fire or Discoloration of Temperature Sensitive Fabrics. Do not use as a residential or household heater. Keep combustible material and such fabrics away from heater. Do not operate heater where flammable vapors, gases or liquids are present. Heaters in the heat mode should not be operated in room temperatures above 130˚F. Fan motor is not designed to operate in ambients below -10˚F. To avoid personal injury read “IMPORTANT INSTRUC- TIONS” on page 2 before installation or operation of heater. Keep electrical cords and combustible materials, such as drapes and other furnishings, away from heater. Electrical Data (60 Hz) Dimensions (In) Model Volts kW Phase Amps BTU Height Width Depth SDRA-30-43 480 30 3 37.2 102,360 38.5 26 44 SDRA-30-93 600 30 3 30.0 102,360 38.5 26 44 SDRA-48-43 480 48 3 58.9 163,776 38.5 30-1/4 44 SDRA-48-93 600 48 3 47.3 163,776 38.5 30-1/4 44 SDRA-60-43 480 60 3 73.3 204,720 38.5 30-1/4 44 SDRA-60-93 600 60 3 58.9 204,720 38.5 30-1/4 44

followed to reduce the risk of fire, electric shock and injury to persons, including the following: 1. Read all instructions before using this heater. 2. This heater is hot when in use. To avoid burns, do not let bare skin touch hot surfaces. If provided, use handles when moving this heater. Keep combustible materials, such as furniture, pillows, bedding, papers, clothes, and curtains at least 3 feet (0.9m) from the front of the heater and keep them away from the sides and rear. 3. Extreme caution is necessary when any heater is used by or near children or handicapped individuals and whenever the heater is left operating and unattended. 4. Always disconnect heater when not in use. 5. Do not operate any heater with a damaged cable or plug or after the heater malfunctions, has been dropped or damaged in any manner. Return heater to authorized service facility for examination, elec- trical or mechanical adjustments, or repair. 6. Do not use outdoors. 7. This heater is not intended for use in bathrooms, laundry areas and similar indoor locations. Never locate heater where it may fall into a bathtub or other water container. 8. Do not run cord under carpeting. Do not cover cord with throw rugs, runners or the like. Arrange cord away from traffic area and where it will not be tripped over. 9. To disconnect heater, turn thermostat off, then remove plug from outlet. 10. Connect to properly grounded outlets only. 11. Do not insert or allow foreign objects to enter any ventilation or exhaust opening as this may cause an electric shock, fire or dam- age the heater. 12. To prevent a possible fire, do not block air intakes or exhaust in any manner. Do not use on soft surfaces, like a bed, where opening may become blocked. 13. A heater has hot and arcing or sparking parts inside.Do not use it in areas where gasoline, paint, flammable liquids are used or stored. 14. Use this heater only as described in this manual. Any other use not recommended by the manufacturer may cause fire, electric shock or injury to persons. 15. This heater is not intended for use with an extension cord. 16.SAVE THESE INSTRUCTIONS. WIRING ELECTRIC 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. 1. Use heater only on the voltage and frequency specified on the nameplate. 2. All wiring should be done in accordance with local codes and the National Electrical Code by a qualified person. 3. Branch circuit wire for connection to heater must be at least 90˚C wire. 4. The top access panel is secured by 4 screws that must be loosened to gain access. 5. A ground terminal is provided near the power terminal board. The ground wire should be connected before other connections are made. 6. Refer to Table A for proper size “SO” grade of cable. 7. A proper strain relief must be used with “SO” grade cable. 8. Dragon heaters are factory pre-wired for 3-phase delta operation. Some units can be converted to single phase operation by chang- ing the wiring. The appropriate wiring diagram is also located on the back of the wiring compartment cover. Cord Preparation for Chromalox Portable Heaters 1. Determine the gage and number of conductors from the tabulation below using amps and phase from the heater nameplate. It is not recommended that cord exceed 50 feet in length. Model Number Volts kW Phase Amps Min Wire Size SDRA-30-43 480 30 3 37.2 6 Ga SDRA-30-63 600 30 3 30.0 8 Ga SDRA-48-43 480 48 3 58.9 4 Ga SDRA-48-63 600 48 3 47.3 4 Ga SDRA-60-43 480 60 3 73.3 2 Ga SDRA-60-63 600 60 3 58.9 4 Ga SET-UP AND OPERATION The SDRA SuperDragon is designed to be used with 20” diameter flexible duct. A feature of the heater is that the fan speed can be easily adjusted from 1500 to 2300rpm, (SDRA heaters are shipped from the factory with the fan speed set at 1800 rpm). The maximum external static load for the blower is .38” H2O, regardless of the fan speed selected. The outlet temperature is controlled by a built-in thermostat- ic control; the maximum outlet temperature is a function of the kW rat- ing and the amount of air (cfm) flowing through the heater. The addi- tion of flexible duct will provide additional static load, resulting in a lower cfm, the lower air flow will reaise maximum outlet temperature until the static load reaches .38”H2O. Exceeding the maximum static load will result in the tripping of the overtemperature control. The per- formance range of the SDRA units is as shown in table B. The motor and fan have variable pitch pulleys for changing the air flow and the ΔT. Graphs 1, 2 and 3 provide the performance data for each size heater at the recommended minimum, medium and maxi- mum fan speeds. The curves end at the point where the .38” H2O stat- ic load has been reached. The temperature rise is based on using Chromalox 20” diameter FX-20 flexible duct. The performance curves were determined by actual testing; therefore using flexible duct not supplied by Chromalox may vary the results. The introduction of bends in the ducting will add static load equivalent to adding 15 feet of duct length for each 90˚ bend and 25 feet of duct length for each 180˚ bend. Δ T Max. ΔT at Max. kW Fan RPM CFM No Load Static Load Static Load 30 1800 2200 42˚F .38” H2O 86˚F 48 1800 2200 68˚F .38” H2O 144˚F 60 1800 2200 88˚F .38” H2O 170˚F Table A Table B

30 kW 100 75 50 25 0 0 100 75 50 25 125 150 175 Duct Length in Feet Temperature Rise ˚F 1500 RPM 1800 RPM 2200 RPM Temperature Rise vs Duct Length 48 kW 100 60 40 20 0 0 100 75 50 25 125 150 175 Duct Length in Feet Temperature Rise ˚F 120 140 160 1800 RPM 2200 RPM 1500 RPM 80 Temperature Rise vs Duct Length 60 kW 100 60 40 20 00 100 75 50 25 125 150 175 Duct Length in Feet Temperature Rise ˚F 120 140 160 1800 RPM 2200 RPM 1500 RPM 80 180 200 SDRA heaters can be easily field if modified to vary the fan speed. There may be some circumstances where the use of short lengths of duct may not create sufficient pressure drop to achieve the desired tem- perature rise. This may also be the case of using the unit without a duct. This insufficient static pressure drop may result in high air flow, with the maximum temperature rise below the desired level, (even after the fan speed has been reduced to the minimum rpm). An accessory AD- 16, adjustable damper, is available and can be attached to the heater to produce a static load, ranging from .1” to .19” H2O which will act to reduce the amount of air flow. The “Friction Loss” Graph 4 provides the actual test data on the friction loss for the AD-16 damper attachment. The losses are stated as the equivalent length in feet of 20” duct. Friction Loss AD-16 Damper 10 60 40 20 0 2000 1600 1400 1800 2200 2400 Fan RPM Equivalent Duct Length FT 30 50 70 80 90 Damper Full Closed Damper Full Open The SDRA Dragon includes 2 thermostats. The thermostat on the air inlet end of the unit is for the minimum air temperature desired. The thermostat on the discharge end of the heater is for the maximum air temperature desired. The two thermostats are wired in series with the heating element contactor coil. The temperature range of both ther- mostats is 60 - 180˚F. Adjustable Damper and Duct Adaptor Rear of Heater Front of Heater Adjustable Damper 1/4-20 Wing nut Provided with AD-16 Duct Adapter

Changing the Pitch Diameter of the Sheaves: 1. Tools required: 5/32” allen wrench, 3/8” nut driver, 9/16” box wrench and a medium size phillips screwdriver. 2. Remove the lower belt cover by removing the (5) sheet metal screws. 3. Remove the rear grille by removing the (4) 1/4” bolts and nuts. 4. Remove the belt cover inside the blower by removing the (4) sheet metal screws. 5. Loosen the (4) bolts, (2) on each side. See Fig. 1. 6. Loosen the (2) motor tension lock nuts and the fan belt tension adjusting bolts. See Fig.2 7. Loosen the set screw on the fan pulley or motor pulley. Fig. 3 shows the construction of the fan pulley, the motor pulley is the same construction. 8. Rotate the front half of the pulley clockwise until it bottoms, then rotate counter clockwise until the set screw aligns with the flat in the threaded half of the pulley. The pulley is now in position for adjustment. See Table 1 for the number of turns out. Tip: Leave allen wrench in set screw and use free hand to fold fan blade. 9. Retighten set screw, use of thread locking compound is recom- mended. 10. Adjust fan belt tension, see Fig. 2. A 1/2” of belt deflection is rec- ommended. Tighten lock nuts. 11. Tighten the 3/8” bolts, see Fig. 1 12. Rotate fan blade to make sure the fan belt does not rub. 13. Reinstall top belt cover, grille and lower belt cover. Tip: Installing the grille before installing the lower cover makes it easier to access the two lower grille bolts. Table 1 Fan No. of turns from full closed Fan No. of turns from full closed RPM Motor Pulley Fan Pulley RPM Motor Pulley Fan Pulley 1500 3 1-1/2 1950 1-1/2 3 1600 2-1/2 1-1/2 2000 1-1/2 3-1/2 1650 2 1-1/2 2100 1-1/2 4 1725 1-1/2 1-1/2 2200 1-1/2 4-1/2 1800 1 1-1/2 2300 1 4-1/2 1850 1/2 1-1/2 4 Figure 1 Figure 2 Figure 3 3/8” Bolts Lock Nuts Fan belt tension adjusting bolts 3/8” Bolts Fan belt tension adjusting bolts

SDRA 48kW, 480V, 3PH SDRA 60kW, 480V, 3PH Attach all Wires on this Side of Contactor to Auxillary Terminals Blk/Red or Grey Blk Transformer Control Enclosure Blk Wht Run these Wires Through 1" Conduit Contactor Motor Relay Toggle Switch L1 L2 L3 Motor P4 P5 P6 T3 T1 T2 T9 T8 T7 T4 T6 T5 Inlet Thermostat Outlet Thermostat Cutout 12 1 Front of Heater 10 Heater Terminal Box 4 Motor Relay Control Enclosure 45 Amp Fusing 30 Amp Fusing L1 L3 L2 Wht Transformer Contactor Contactor Blk Toggle Switch Amber Pilot Light Green Pilot Light Run these Wires Through 1/2" Conduit Motor P4 P5 P6 T3 T1 T2 T9 T8 T4 T6 T5 T7 Inlet Thermostat Outlet Thermostat Cutout 1 14 1 17 18 15 13 12 Front of Heater Heater Terminal Box 4 10 Run these Wires through 1/4" Conduit One end attached to screw in terminal box and other end attached to screw on sub panel. Motor Relay Control Enclosure 50 Amp Fusing 50 Amp Fusing L1 L3 L2 Wht Transformer Contactor Contactor Blk Toggle Switch Amber Pilot Light Green Pilot Light Run these Wires Through 1/2" Conduit Motor P4 P5 P6 Inlet Thermostat Outlet Thermostat Cutout 14 1 17 15 13 12 Heater Terminal Box 4 10 Run these Wires through 1/4" Conduit One end attached to screw in terminal box and other end attached to screw on sub panel. T3 T1 T2 T9 T8 T4 T6 T5 T7 1 1 18 22 20 2 24 23 Front of Heater

and Routing of Thermostat Capillary and Mounting of Bulb 19 12 11 11 11 12 12 12 11 11 11 12 12 Front of Heater View Showing Element Placement and Routing of Thermostat Capillary and Mounting of Bulb (30-1/4) Twist Wire (20-1/2) 38 37 (44) (38-1/2) 16 84 36 45 80 81 20 21 18 32 21 Back of Heater Side View Detail Showing Pulley and Belt Installation Motor Pulley Fan Pulley 77 79 78 23 Element Assembly 30kW Element Assembly 60kW Front View with Grille Removed (All Sizes) Element Assembly 48kW Side View shown with Heater and Control Terminal Box Covers Removed All Sizes

power supply before servicing and/or inspecting the heater; failure to do so may result in electrical shock. Replace or repair damaged cords or plugs immediately. Check tight- ness of all electrical connections prior to energizing Dragon. Blow out or vacuum away any dirt or debris that may have accumulated around the control enclosure fan motor or heating elements. RENEWAL PARTS IDENTIFICATION PARTS COMMON TO ALL UNITS Item Description Part No. 18 Temperature Control 300-019560-002 19 Hi-Limit Cut-out 300-049200-004 23 Toggle Switch 292-046123-001 32 Blower Assembly 021-304823-009 33 Inlet & Outlet Grille 134-304780-002(2) 36 Caster / Locking 375-122535-007 37 Handle - Right Side 139-304779-003 38 Handle - Left Side 139-304779-004 45 Semipneumatic Wheel 333-557518-004(2) 77 Pulley Var. Pitch 7/8” 225-305091-004 78 Pulley Var. Pitch 5/8” 225-305091-003 79 Pulley Belt 017-049702-009 86 Pilot Light - Green 213-122066-043 87 Pilot Light - Amber 213-122066-042 94 Thermostat Knob 169-300468-003 95 Thermostat Label 220-019122-010 Element (11) Element (12) Motor (16) Contactor (20) Transformer (21) Fuse Block (80) Fuse (81) Term. Block (84) Model No. Volts kW Phase Part No. Part No. Part No. Part No. Part No. Part No. Part No. Part No. SDRA-30-43 480 30 3 118-304793-011(3) 118-304793-013(3) 193-121843-232 072-304551-008 315-304252-001 N/A N/A N/A* SDRA-30-93 600 30 3 118-304793-012(3) 118-304793-014(3) 193-121843-233 072-304551-008 315-304252-003 N/A N/A N/A* SDRA-48-43 480 48 3 118-304793-011(3) 118-304793-013(6) 193-121843-232 072-304551-008(2) 315-304252-001 129-025643-001 128-026510-005(3) 303-047468-004 SDRA-48-93 600 48 3 118-304793-012(3) 118-304793-014(6) 193-121843-233 072-304551-008(2) 315-304252-003 129-025643-001 128-026510-005(3) 303-047468-004 SDRA-60-43 480 60 3 118-304793-011(6) 118-304793-013(6) 193-121843-232 072-304551-008(2) 315-304252-001 129-025643-001(2) 128-026510-006(6) 303-047468-004 SDRA-60-93 600 60 3 118-304793-012(6) 118-304793-014(6) 193-121843-233 072-304551-008(2) 315-304252-003 129-025643-001(2) 128-026510-006(6) 303-047468-004 * Wired directly to contactor. All units contain two sets of elements. The ratings of the elements on the discharge end have a lower wattage than the elements on the inlet end of heater. The ends of the elements are color coded, the lower wattage are color coded yellow and the higher wattage are color coded blue. a. Lower wattage elements, discharge end, yellow coded b. Higher wattage elements, fan end, blue coded

Phone: 1-800-368-2493 www.chromalox.com Limited Warranty: Please refer to the Chromalox limited warranty applicable to this product at http://www.chromalox.com/customer-service/policies/termsofsale.aspx.