Osram 038821 User manual

OPERATING INSTRUCTIONS OSRAM
1/24/01 SYLVANIA
Process Heat
131 Portsmouth Ave. Exeter, NH 03833 USA Tel: [phone] Fax: [phone]
THREADED INLINE HEATERS
038821, 038822, 038823, 038824,
038825, 038826, 063007
⇒FOR SAFETY AND LONG HEATER LIFE, CAREFULLY READ THIS MANUAL BEFORE USE.
Description
Stainless Steel threaded heaters for heating high-pressure air or inert gases to 1400°F (760°C). Sizes from 3/8”
to 2-1/2” diameter, and in wattages from 1.6 to 18 Kilowatts. If operated correctly, the heater will operate
continuously for 5000 hours or longer.
Specifications
MAXIMUM INLET PRESSURE 150 PSI (10 BAR)
PART
NUMBER
MAXIMUM
WATTS
MAXIMUM
VOLTS
MAXIMUM
AMP DRAW
MAXIMUM
TEMP.
(°F/°C)
STYLE
038821 1600 170 9.4 1400/760 A
038822 1600 170 9.4 1400/760 B
038823 4000 220 18.2 1400/760 A
038824 4000 220 18.2 1400/760 B
038825 6000 220 27.3 1000/540 A
038826 6000 220 27.3 1000/540 B
063007 18000 240 75 (1ph)/
44 (3ph)
1000/540 B
Safety
SHOCK HAZARD Only qualified individuals should install this heater and related controls. Follow all applicable
electrical codes and use proper wiring.
BURN/FIRE/EXPLOSION HAZARD Do not use with or near explosive or reactive gases. Avoid contact with the
side, or exposure to the exit-end, during or soon after operation. DO NOT USE NEAR VOLATILE OR
COMBUSTIBLE MATERIALS.
Precautions
Use filtered air. Avoid grease, oil, or oil vapors, corrosive or reactive gases which will damage heater.
Operate at safe voltages as shown on the PERFORMANCE CURVES. Excess voltage will cause premature
failure.

OPERATING INSTRUCTIONS OSRAM
1/24/01 SYLVANIA
Process Heat
131 Portsmouth Ave. Exeter, NH 03833 USA Tel: [phone] Fax: [phone]
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).

OPERATING INSTRUCTIONS OSRAM
1/24/01 SYLVANIA
Process Heat
131 Portsmouth Ave. Exeter, NH 03833 USA Tel: [phone] Fax: [phone]
Warranty
OSRAM SYLVANIA warrants that all products to be delivered hereunder will be free from defects in material and
workmanship at the time of delivery. OSRAM SYLVANIA's obligation under this warranty shall be limited to (at its
option) repairing, replacing, or granting a credit at the prices invoiced at the time of shipment for any of said products.
This warranty shall not apply to any such products which shall have been repaired or altered, except by OSRAM
SYLVANIA, or which shall have been subjected. OSRAM SYLVANIA shall be liable under this warranty only if (A)
OSRAM SYLVANIA receives notice of the alleged defect within sixty (60) days after the date of shipment; (B) the
adjustment procedure hereinafter provided is followed, and (C) such products are, to OSRAM SYLVANIA’s
satisfaction, determined to be defective.
THE WARRANTY SET FORTH IN THE PRECEDING PARAGRAPH IS EXCLUSIVE AND IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, WITHOUT LIMITATION, ANY IMPLIED WARRANTY OF
FITNESS FOR A PARTICULAR PURPOSE OR OF MERCHANTABILITY.
The information contained in this manual is based on data considered to be true and accurate. Reasonable
precautions for accuracy has been taken in the preparation of this manual, however OSRAM SYLVANIA assumes no
responsibility for any omissions or errors, nor assumes any liability for damages that may result from the use of the
product in accordance with the information contained in this manual.
Please direct all warranty/repair requests or inquiries to the place of purchase, and provide the following information,
in writing:
(A) Order number under which products were shipped
(B) Model/Serial Number of product
(C) Reason for rejection
PRODUCTS CAN NOT BE RETURNED TO OSRAM SYLVANIA WITHOUT AUTHORIZATION.
Replacement, repair, or credit for products found to be defective will be made by the place of purchase. All products
found to be not defective will be returned to the Buyer; transportation charges collect or stored at Buyers expense.

OPERATING INSTRUCTIONS OSRAM
1/24/01 SYLVANIA
Process Heat
131 Portsmouth Ave. Exeter, NH 03833 USA Tel: [phone] Fax: [phone]

OPERATING INSTRUCTIONS OSRAM
1/24/01 SYLVANIA
Process Heat
131 Portsmouth Ave. Exeter, NH 03833 USA Tel: [phone] Fax: [phone]

OPERATING INSTRUCTIONS OSRAM
1/24/01 SYLVANIA
Process Heat
131 Portsmouth Ave. Exeter, NH 03833 USA Tel: [phone] Fax: [phone]