Chromalox STAR Series User manual

1
PG434-6
161-304901-002
March 2016
Installation and Operation Instructions
STAR Radiant Heater
for Fixed Overhead Installations

2
Table 1 - Specifications
Model Figure Volts kW
Amperage
BTU
Dimensions (In.) Wire Gauge (Min.)
1 Phase 3 Phase A (Length) B (Width) D (Depth) 1 Phase 3 Phase
STAR-02A-11-F
1
120 1.5 12.5 NA 5118
33-1/4 15-1/2 11-9/16
14 NA
STAR-02A-81-F 208 2 9.6 NA 6824 14 NA
STAR-02A-21-F 240 2 8.3 NA 6824 14 NA
STAR-02A-71-F 277 2 7.2 NA 6824 14 NA
STAR-02A-41-F 480 2 4.2 NA 6824 14 NA
STAR-02A-61-F* 600 2 3.3 NA 6824 14 NA
STAR-05A-81-F 208 4.5 21.6 NA 15354
55-3/4 15-1/2 11-9/16
12 NA
STAR-05A-21-F 240 4.5 18.8 NA 15354 12 NA
STAR-05A-71-F 1 277 4.5 15.9 NA 15354 14 NA
STAR-05A-41-F 480 4.5 9.4 NA 15354 14 NA
STAR-05A-61-F* 600 4.5 7.5 NA 15354 14 NA
STAR-06A-83-F 208 6 28.8 16.7 20472
32-1/2 23-5/8 11-1/2
10 12
STAR-06A-23-F 240 6 25.0 14.4 20472 10 12
STAR-06A-71-F 2 277 6 21.7 — 20472 10 —
STAR-06A-43-F 480 6 12.5 7.2 20472 12 12
STAR-06A-63-F* 600 6 10.0 5.8 20472 12 12
STAR-14A-83-F 208 13.5 NR 37.5 46062
55-5/8 23-5/8
NR 10
STAR-14A-23-F 240 13.5 NR 32.5 46062 NR 10
STAR-14A-71-F 2 277 13.2 47.7 — 45038 11-3/4 8 ––
STAR-14A-43-F 480 13.5 28.1 16.2 46062 12 12
STAR-14A-63-F* 600 13.5 22.5 13.0 46062 12 12
* Not UL or CSA NA - Not Available NR - Not Recommended
11-9/16"
15-1/2"
33-1/4"
B
11-9/16"
15-1/2"
55-3/4"
23-5/8"
55-5/8"
11-1/2"
23-5/8"
32-1/2"
11-1/2"
2.0 kW 4.5 kW
6.0 kW 13.5 kW
Figure 1
Figure 2

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STAR Radiant Heater for Fixed Overhead Intallations
FIRE HAZARD. Do not use as a residential or house-
hold heater. Keep combustible material away from
heater. Do not operate heater where flammable va-
pors, gases or liquids are present.
To avoid personal injury read “IMPORTANT INSTRUC-
TIONS” on this page before installation or operation
of heater.
ELECTRIC SHOCK AND FIRE HAZARD. This radiant
heater is a component of the complete heating sys-
tem. The heating system designer must consider
the risks associated with its operation and specify
adequate controls and safety devices. Where the
consequences of failure could result in personal in-
jury, property damage or fire, back-up controls are
essential.
IMPORTANT: SAVE THESE INSTRUCTIONS
Installation
The Chromalox STAR radiant heater is shipped fully assem-
bled. The heater can be hung from the ceiling with 4 chains or
rigid angle brackets attached to the heater brackets located
on the back of the heater, for 2 and 4.5 kW heaters, chains
can be attached to the four holes in the corners of the back
reflector. (Chromalox offers hanging chain kits for these heat-
ers that will allow for installations 2 to 6 feet from the ceiling.)
Minimum spacings:
Ceiling to top of heater is 2 feet.
Wall to sides of heater is 3 feet.
Floor to bottom of heater is 10 feet.
Installer should consult state and local codes and
meet any applicable requirements regarding the in-
stallation.
FIRE HAZARD. Radiant heaters are capable of devel-
oping high temperatures, care should be taken to:
A. Mount heater with the proper clearance between
heater and walls, ceiling and floor.
B. Mount heater in horizontal position only. Do not
mount vertically or tilted in any direction.
C. Do not mount heater over combustible surfaces.
D. Do not stack or store combustible materials di-
rectly below the heater or in the space a dis-
tance of 5 feet from any projected edge of the
heater.
E. Do not operate the heater without Ground Fault
Equipment Protection.
Failure to follow these instructions can result in per-
sonal injury and fire.
5 Feet
Min.
Floor - Non combustible surface
5 Feet
Min.
Shaded area
must be
kept clear of
combustible
materials

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IMPORTANT INSTRUCTIONS
When using electrical appliances, basic precautions should
always be followed to reduce 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. Allow sufficient time for
heater to cool before serviceing or cleaning heater.
3. Do not stack or store combustible materials in the radia-
tion path under the heater or in the space a distance of
5 feet from any projected edge of the heater as shown in
figure 4.
4. Always disconnect heater when not in use.
5. Do not use outdoors in areas subject to wind.
6. Connect to properly grounded outlets or building ground.
7. This heater has hot surfaces. Do not use it in areas where
gasoline, paint or flammable liquids are used or stored.
8. 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.
9. In order to prevent equipment damage, protect with a
ground fault device such as Chromalox STAR-GF series
monitor. An equipment protection device circuit breaker
is also acceptable.
10. SAVE THESE INSTRUCTIONS
Wiring
ELECRIC SHOCK HAZARD. Disconnect all power be-
fore 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.
All electrical wiring must be done by a qualified
person 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.
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 bottomof the
enclosure. The ground wire should be connected before
other connections are made.
5. Refer to Table 1 for proper entrance wiring size.
6. Heater can be wired with rigid or flexible conduit.
7. Unless otherwise noted on wiring diagram label (located
on heater enclosure), all 3 element heaters are factory
pre-wired for 3-phase delta operation. Some units can
be converted to single phase operation by changing the
wiring. Refer to Table 1 for those heaters that can be con-
verted to single phase. The appropriate wiring diagram
(Figure 3) is also located on the bottom of the enclosure.
Three Phase Delta Wiring Single Phase Wiring
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.

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Optional Accessories
Chromalox STAR series radiant heaters can be field modified
by adding optional kits. Refer to Chart A to select the proper
kit.
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 modification. See instruction bulletin PG435 for details.
Grill Kit
The grill kit consists of one (1.5, 2, 4.5 and 6 kW) or 2 grill
sections (13.5kW) and hardware to protect personnel from
coming into contact with hot radiant heating elements. See
instruction bulletin PG437 for details.
Disconnect Kit
The disconnect kit consists of a complete assembly con-
sisting of a disconnect switch (3 Pole), power terminal block
and all hardware 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.
Hanger Kit
Hanger kits include 24 feet of chain and four S hooks to
mount the unit in a fixed overhead position using the univer-
sal mounting brackets included on the heater. This kit allows
installation distances from the ceiling of 2 feet to 6 feet. See
installation diagram Fig. 4 on page 2.
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 disconnect switch (if used). See installation bulletin
PF491 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.
STAR-TG Kit combines the tip over and ground fault feature
for portable heaters. See installation bulletin PG436.
Chart A - Kit Selection Guide
Model Grill Kit Disconnect Kit Hanger Kit
Wall Mount
Ground Fault
Portable Cart
Kit **
STAR-02A-11-F PCN 111878 PCN 340662 PCN 340654 NA NA
STAR-02A-81-F PCN 111878 PCN 340662 PCN 340654 PCN 340777 NA
STAR-02A-21-F PCN 111878 PCN 340662 PCN 340654 PCN 340785 NA
STAR-02A-71-F PCN 111878 PCN 340662 PCN 340654 PCN 340793 NA
STAR-02A-41-F PCN 111878 PCN 340662 PCN 340654 PCN 340806 NA
STAR-02A-61-F PCN 111878 PCN 340662 PCN 340654 PCN 340814 NA
STAR-05A-81-F PCN 111894 PCN 340662 PCN 340654 PCN 340777 PCN 340620
STAR-05A-21-F PCN 111894 PCN 340662 PCN 340654 PCN 340785 PCN 340620
STAR-05A-71-F PCN 111894 PCN 340662 PCN 340654 PCN 340793 PCN 340620
STAR-05A-41-F PCN 111894 PCN 340662 PCN 340654 PCN 340806 PCN 340620
STAR-05A-61-F PCN 111894 PCN 340662 PCN 340654 PCN 340814 PCN 340620
STAR-06A-83-F PCN 340638 PCN 340662 PCN 340654 PCN 340777 PCN 340830
STAR-06A-23-F PCN 340638 PCN 340662 PCN 340654 PCN 340785 PCN 340830
STAR-06A-71-F PCN 340638 PCN 340662 PCN 340654 PCN 340793 PCN 340830
STAR-06A-43-F PCN 340638 PCN 340662 PCN 340654 PCN 340806 PCN 340830
STAR-06A-63-F PCN 340638 PCN 340662 PCN 340654 PCN 340814 PCN 340830
STAR-14A-83-F PCN 340857 PCN 340662 PCN 340654 PCN 340777 PCN 340849
STAR-14A-23-F PCN 340857 PCN 340662 PCN 340654 PCN 340785 PCN 340849
STAR-14A-71-F PCN 340857 PCN 340662 PCN 340654 PCN 340793 PCN 340849
STAR-14A-43-F PCN 340857 PCN 340662 PCN 340654 PCN 340806 PCN 340849
STAR-14A-63-F PCN 340857 PCN 340662 PCN 340654 PCN 340814 PCN 340849
* Includes Grill(s)

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Maintenance
ELECRIC SHOCK HAZARD. Disconnect all power be-
fore servicing or replacing heating elements.
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 disen-
gage box from conduit /cable fitting.
3. Remove safety grills (if installed).
4. Remove retainer screw located on the reflector at the ter-
minal end.
5. Loosen (2), 3/8” nuts from the terminal box bracket locat-
ed on the back of the heater and slide the entire heating
element assembly out of the reflector assembly.
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” ele-
ments. Use of other elements will cause excess tempera-
tures inside terminal box.
9. Place gasket on the bulkhead fitting and insert terminals
and fittings 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).
Renewal Parts Identification
Chart A - Kit Selection Guide
Model Element***
Element Housing
Reflector Safety Screen Terminal Gasket Box
STAR-02A-11-F PCN 106059 234-891755-004 PCN 111878 132-304879-004
STAR-02A-81-F PCN 106067 234-891755-004 PCN 111878 132-304879-004
STAR-02A-21-F PCN 106075 234-891755-004 PCN 111878 132-304879-004
STAR-02A-71-F PCN 106083 234-891755-004 PCN 111878 132-304879-004
STAR-02A-41-F PCN 106091 234-891755-004 PCN 111878 132-304879-004
STAR-02A-61-F PCN 106104 234-891755-004 PCN 111878 132-304879-004
STAR-05A-81-F PCN 106403 234-891755-002 PCN 111894 132-304879-004
STAR-05A-21-F PCN 106411 234-891755-002 PCN 111894 132-304879-004
STAR-05A-71-F PCN 106796 234-891755-002 PCN 111894 132-304879-004
STAR-05A-41-F PCN 106964 234-891755-002 PCN 111894 132-304879-004
STAR-05A-61-F PCN 106972 234-891755-002 PCN 111894 132-304879-004
STAR-06A-83-F PCN 106067 234-891755-004 PCN 340638 132-304879-003
STAR-06A-23-F PCN 106075 234-891755-004 PCN 340638 132-304879-003
STAR-06A-71-F PCN 106083 234-891755-004 PCN 340638 132-304879-003
STAR-06A-43-F PCN 106091 234-891755-004 PCN 340638 132-304879-003
STAR-06A-63-F PCN 106104 234-891755-004 PCN 340638 132-304879-003
STAR-14A-83-F PCN 106403 234-891755-002 PCN 340857 132-304879-003
STAR-14A-23-F PCN 106411 234-891755-002 PCN 340857 132-304879-003
STAR-14A-71F PCN 106796 234-891755-002 PCN 340857 132-304879-003
STAR-14A-43-P PCN 106964 234-891755-002 PCN 340857 132-304879-003
STAR-14A-63-P PCN 106972 234-891755-002 PCN 340857 132-304879-003
*** 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
Limited Warranty:
Please refer to the Chromalox limited warranty applicable to this product at
http://www.chromalox.com/customer-service/policies/termsofsale.aspx.
© 2016 Chromalox, Inc. All rights reserved.
Chromalox
103 Gamma Drive
Pittsburgh, PA 15238
[phone]
www.chromalox.com