Research PanelIR 4555 User manual

Model 4555 User’s Manual
Publication #: 107679-001 Rev. A
July 2005
Another quality product from:
7128 Shady Oak Road, Eden Prairie, MN 55344
Phone: [phone] Fax: [phone]
E-mail: [email protected]
www.researchinc.com

Dear Valued Customer:
Thank you for purchasing a Model 4555 PanelIR®Infrared Pyropanel. We believe it is the finest system of its
type and are confident you will think so too.
For technical assistance, training, replacement parts and assemblies, or any other problems or questions, contract
our Field Service specialists. They will do everything they can to help you or will put you in touch with someone
who can.
This instruction manual has been carefully prepared to make sure you get out of your system all of the capabilities
we designed and built into it. To tell us how we could make the system, our support of it, or this manual even
more useful, we invite you to call our product manager with your suggestions and recommendations.
Additional copies of this manual are available at reasonable cost from our Customer Service Department. Once
again, let us welcome you to the growing family of Research, Inc. customers. We look forward to working with
you in the future.
Requirement Appropriate Contact
Additional information regarding application Your local sales representative.
of the Model 4555 system or other Research Inc.
products.
Ordering additional Research Inc. products or Manuals. Your local sales representative or
Research, Inc. Customer Service [phone]
Technical assistance and training. Research Inc. Factory Service
[phone]
Sincerely,
Terry Nigon
President
Research Inc.

Model 4555 PanelIRTM User Manual Contents
Section Page
SAFETY 1
PRODUCT DESCRIPTION 2
Dimensions 7
INSTALLATION
Mechanical Installation 11
Electrical Installation 12
Single Phase Wiring 14
Three Phase Wiring 15
Lamp Installation 19
Thermostat Wiring 20
Pressure Switch Wiring 20
Blower Wiring 21
OPERATING INSTRUCTIONS 22
MAINTENANCE INSTRUCTIONS 23
Appendix A Multiple Heater Wiring 24

Model 4555 PanelIRTM User Manual Safety
General
Electrical
Safety
Heater
Safety
Infrared
Radiation
Safety
The Model 4555 Heater is designed for safe operation. Nevertheless, installation,
maintenance, and operation of the heater can be dangerous for a careless operator or
maintenance person. For your safety and the safety of others, read the instructions in this
manual and follow these warnings to help prevent accident or injury.
Due to high voltages present in typical Model 4555 installations there is danger of
electrical shock when installing, operation, or servicing the heater. Exercise extreme
caution when handling or working with these high voltages.
All applicable local and national electrical codes should be followed to ensure proper
installation and operation of the Model 4555. A safe electrical ground must also be
provided and properly installed on the heater before attempting to operate the unit.
WARNING!
Power lines and any other affiliated heater circuitry (i.e., blowers, thermostat, etc.)
must be disconnected prior to any servicing issue including lamp installation and
change out.
The Model 4555 heater should never be operated with the end covers of the heater
removed.
The presence of open load-to-ground must be verified after lamp installation into the
Model 4555 and before system power is applied.
Certain areas of the Model 4555 heater may exceed 500° F (260° C) while the heater is in
operation. Exercise extreme care when working in close proximity to an operating heater.
WARNING!
NEVER place any part of the body under or near any part of the heater while power is
applied.
Always allow the heater to cool sufficiently (at least 5 minutes with the blower operating,
longer if the blower is not operating) before servicing any part of the heater, including
lamps or adjacent parts.
CAUTION! Continuous exposure to high-intensity infrared radiation at close
proximity could be harmful to eyes or skin. Although infrared lamps emit negligible ultra
violet electromagnetic radiation, harmful burns can still result if an operator is in close
contact with lamps being operated at high intensity.
Because of the brilliant light emitted by infrared lamps at full intensity, it is recommended
that eyes be shielded from the glare if observing the lamps for an extended period of time.
Use suitable shaded lenses or dark glasses.
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Model 4555 PanelIRTM User Manual Product Description
PRODUCT DESCRIPTION
Model4555
FAST. FOCUSED. CONTROLLED.
InfraredHeat. Applications
InstantaneousResults. •Activating Thermo Transfer
•Ceramic Processing
The Model 4555 High Density Infrared Panel heater is a modular,
panel-type heating unit that combines radiant and convection
heating techniques. A forced air flow system turns waste heat into
usable energy and allows the heater to operate efficiently at very
high power levels. This heater is available with either
•Cure and Melt Powders
•Curing
•Dry and Cure Paint
•Dry Adhesive
•Drying Coatings
medium-wavelength or short wavelength lamps. •Laminating Composites
You also have the choice of a ceramic reflector or an •Pre-Cure
aluminum reflector.
•Preheating
•Resin Curing
•Soldering/ Desoldering
•Structural Tests
•Thermoforming
•Thick Film Drying
•Vulcanizing
•Weld Stress Relief
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Model 4555 PanelIRTM User Manual Product Description
ProductDescription-PanelIR4555
HeaterConstruction
Metal Housing
The Model 4555 PanelIR uses rugged stainless steel and aluminum housing to contain the lamps, blowers and reflector.
Reflector
A polished aluminum or ceramic reflector is installed in the housing in back of the lamps to direct the heat toward the product. The
choice of ceramic or polished aluminum is based on the application.
Polished Aluminum Reflector
Polished Aluminum Reflectors are the most commonly used. They have a lower thermal mass than ceramic and as a result,
they allow the heater to respond quicker to changes in the lamp temperature.
Ceramic Reflector
A ceramic reflector is generally used for applications where smoke or dirt are released as a part of the process.
These contaminates will burn off of the ceramic reflector during operation so the reflector will not require cleaning.
The ceramic reflector is heavier than a polished aluminum reflector and has more thermal mass to it to take as
much as 10 minuets to heat up to operating temperature and to cool down when the lamps are shut off.
Forced Air Blowers
Blowers are installed in the housing behind the reflector. The blowers pressurize the chamber behind reflector and force air through the
holes in the reflector to enhance the heating capability of the panel and to cool the end seals on the lamps.
FORCED AIR BLOWERS
METAL HOUSING
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Model 4555 PanelIRTM User Manual Product Description
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ProductDescription-PanelIR4555cont.
HeaterConstructioncont.
Infrared Lamps
Short Wavelength Lamp
These lamps are generally used in applications where a product is to be heated or cured. These lamps may be operated in
horizontal or vertical orientations. Typical short wavelength applications include:
Heat treating metals
Annealing metals
Localized softening plastics for bending or forming
Curing silicone and other rubber extrusions
*Limitations
Absorption of short wavelength is affected by product color. Black and dark colors absorb well. Heating lighter colors may be
more readily achieved with medium wavelength lamps.
Medium Wavelength Lamps
These lamps are generally used in applications where a surface needs to be dried. They may only be operated in a
horizontal orientation.
High speed drying of water or solvent based ink
Removing water after coil coating
Heating substances such as Teflon that do not absorb short wavelength
Heating lighter colored surfaces
*Limitations
Medium wavelength does not penetrate as deeply into metals, plastics, or rubber as short wavelength. They may only be
operated in a horizontal orientation.
CERAMIC OR ALUMINUM REFLECTOR
LAMPS

Model 4555 PanelIRTM User Manual Product Description
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ProductDescription-PanelIR4555cont.
Controls
The model 4555 PanelIR heater is designed to be powered by one of the standard Research Inc. control panels. The model of the
control panel required depends on (1) the voltage and amperage required to power the panel, (2) the electrical service in the facility,
and (3) the type of temperature control required for the process.
The 900 series control panels are for single phase power and the 925 series panels are for three phase power. Both series can be
specified with circuit breakers from 20 amps to 80 amps and with manual or set point control.
Terminal blocks inside the panel allow convenient termination for incomingpower, all lamps and the forcedair blower. A step down
transformer is included in the 480 volt panel to power the 220 volt blowers.
Power Controller Chart for Model 4555 PanelIR
This chart shows the control panels that are available for all sizes of the Model 4555 PanelIR heater.
925-480-80 Model 4555-38-12
925-480-60Model 4555-38-09
925-480-30
925-480-60
925-480-30
925-480-30
925-480-30
N/A
925-480-30
480 Volt 3 Phase
925-240-60
925-240-60
925-240-30
925-240-30
925-240-30
925-240-30
925-240-30
240 Volt 3 Phases
900-240-40Model 4555-10-09
900-240-40Model 4555-10-06
900-240-60Model 4555-16-06
Model 4555-16-09
900-240-60Model 4555-10-12
900-240-40Model 4555-05-12
900-240-20Model 4555-05-06
Model 4555-16-12
Model 4555-25-09
Model 4555-38-06
Model 4555-25-12
Model 4555-25-06
Power Controller
240 Volt 1 Phase
Heater Module

Model 4555 PanelIRTM User Manual Product Description
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B
A
C

Model 4555 PanelIRTM User Manual Product Description
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ProductDescription-PanelIR4555
12.62 inch
12.62 inch
8.62 inch
12.62 inch
8.62 inch
16 inch
16 inch
16 inch
B
24 inch
24 inch
20 inch
24 inch
20 inch
20 inch
20 inch
20 inch
A C
8.62 inch
8.62 inch
8.62 inch
20 inch
24 inch
20 inch
24 inch
24 inch
Dimensions
80 amp480 VoltModel 925-480-80
60 amp480 VoltModel 925-480-60
30 amp480 VoltModel 925-480-30
60 amp240 VoltModel 925-240-60
30 amp224 VoltModel 925-240-30
Three Phase
60 amp240 VoltModel 900-240-60
40 amp240 VoltModel 900-240-40
20 amp240 VoltModel 900-240-20
Single Phase
Circuit BreakerVoltageControl Panel
ControlOptions
All panels have an operator interface that allowed the heater to be controlled in any one of three operator selected modes.
Manual Operation
The digital control is used to directly set the percent output of the lamps from 0 to 100%.
Automatic-Temperature Control
The controller takes the input from a type “K” thermocouple or IR sensor and regulates the lamp output so the product temperature will
match the preset value.
Automatic-Line Speed
The controller will take the output from a 0 to 10 VDC line that references line speed and vary the lamp output from 0 to 100%
proportionally.
Once you have determined the appropriate size Model 4555 PanelIR Heater, please refer to the Power Controller to select the correct
controller for your application.

Model 4555 PanelIRTM User Manual Product Description
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SPECIFICATIONS–PanelIR4555
Dimensions –PanelIR4555
42.4112.0010.7541.5838 (965)Model 4555-38-12
42.419.007.7541.5838 (965)Model 4555-38-09
42.416.005.3841.5838 (965)Model 4555-38-06
29.4112.0010.7528.5825 (636)Model 4555-25-12
29.419.007.7528.5825 (636)Model 4555-25-09
29.416.005.3828.5825 (636)Model 4555- 25-06
20.4112.0010.7519.5816 (406)Model 4555-16-12
20.419.007.7519.5816 (406)Model 4555-16-09
20.416.005.3819.5816 (406)Model 4555-16-06
14.4112.0010.7513.5810 (254)Model 4555-10-12
14.419.007.7513.5810 (254)Model 4555-10-09
14.416.005.3813.5810 (254)Model 4555-10-06
9.4112.0010.758.585 (127)Model 4555-05-12
9.416.005.388.585 (127)Model 4555-05-06
Dimension
D
Dimension
C
Dimension
B
Dimension
A
Lighted
Length(in/mm)
MODEL

Model 4555 PanelIRTM User Manual Product Description
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HowtoOrder–PanelIRModel4555
1.FirstSpecifytheheater
Description
Model
None00
*Example:4555-05-06-SW-
A
R-00
Custom OptionsCode
A
luminum Reflector
Ceramic Reflector
A
R
CR
Reflector TypeCode
Medium-Wave
Watt-Short-Wave
MW
SW
6 Inches (152 mm)
9 Inches (229 mm)
12 Inches (254 mm)
06
09
12
Lamp TypeCode
Lamp WidthCode
5 inches (127mm)
10 inches (254 mm)
16 Inches (406 mm)
25 Inches (635 mm)
38 Inches (965 mm) Short wave lamps only
5
10
16
25
38
LengthCode
PanelIR High Density Area Infrared Heater w / fan (s) Pressure Switch and Thermostat4555
PRODUCT DESCRIPTIONS PanelIR Model 4555
2.Second–SpecifythePowerController
925-480-80Model 4555-38-12 925-480-60Model 4555-38-09 925-480-30
925-480-60
925-480-30
925-480-30
925-480-30
N/A
925-480-30
480 Volt 3 Phase
925-240-60
925-240-60
925-240-30
925-240-30
925-240-30
925-240-30
925-240-30
240 Volt 3 Phase
900-240-40Model 4555-10-09 900-240-40Model 4555-10-06
900-240-60Model 4555-16-06Model 4555-16-09
900-240-60Model 4555-10-12
900-240-40Model 4555-05-12 900-240-20Model 4555-05-06
Model 4555-16-12
Model 4555-25-09
Model 4555-38-06Model 4555-25-12
Model 4555-25-06
Power Controller
Heater Module
240 Volt 1 Phase

Model 4555 PanelIRTM User Manual Product Description
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Accessories&ReplacementParts–PanelIR4555
Additional Operation ManualM4555
25 inch, 2500 watt106656-004
16 inch, 1875 watt106656-003
10 inch, 1000 watt106656-001
Medium Wavelength Lamps
38 inch, 3800 watt103390-010
25 inch, 2500 watt103390-007
16 inch, 1000 watt103390-005
10 inch, 1600 watt103390-003
5 inch, 500 watt103390-001
Short Wavelength Lamps
38 inches (965 mm) lengthER-4555/4-38
10 inches (254 mm) lengthER-4555/4-10
5 inch (127 mm) lengthER-4555/4-05
25 inches (635 mm) lengthER-4555/4-25
16 inches (406 mm) lengthER-4555/4-16
Set of two edge reflectors for:
DescriptionModel
ACCESSORIES AND REPLACEMENT PARTS PanelIR 4555
Mounting
The back of the Model 4555 has four 1/4-20 X 1/2 inch screws installed for mounting purposes.
OptionalEdgeReflectors
Edge reflectors are available to restrict the radiant energy to a rectangular area. The edge reflectors are constructed from the same
materials used in the heater modules. Edge reflectors are specified in the model number or as accessories (in pairs), ordered separately
from the Model 4555 heater. For arrays of multiple hookups, only one set of edge reflectors is required for the array.

Model 4555 PanelIRTM User Manual Installation
MECHANICAL
INSTALLATION
Figure 3-1 Typical
installation
drawing for
model 4555
heater.
Installation
Tools Required:
•Phillips Screwdriver
•Slotted Screwdriver
•Hammer
•Metal Punch
•Pliers
•Tape Measure
•Tin snips/Metal cutting scissors.
As shown in Figure 3-1, four ¼-20 screws are provided on the top of the Model 4555
heater for mounting purposes. The heater can be attached directly to a suitable frame
structure or mounting brackets using these four screws. The distance between the heater
and target should be determined before mounting the heater. The heater should be
mounted so that each end cover may easily be removed for lamp installation.
Multiple Model 4555 heaters can be mounted side-by-side to form large heating arrays.
Screws (4X)
1/4 - 20
Mounting
Frame
Target
CAUTION!
Heater to
Target Distance
The back and end covers of Model 4555 heaters should not be exposed to
temperatures exceeding 425°F (218°C). The heater should not be
surrounded or enclosed by any type of insulating material.
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Model 4555 PanelIRTM User Manual Installation
ELECTRICAL
INSTALLATION
Figure 3-2 Terminal Strip
and Bus Bar
CAUTION!
All internal wiring of the model 4555 Panel IR should be high
temperature insulated wire as specified below or of an equivalent type:
•Lead wire type PFAH or TFE, 600V Maximum, 250°C maximum, UL
listed.
•Ampacity based on National Electrical Code Table 310.
As shown in Figure 3-2, the Model 4555 contains two electrical terminal blocks, one
each mounted on the internal heater housing, under each heater end cover. These
terminal blocks each contain contact points for electrical connection of each lamp of the
heater. In addition, each terminal strip contains a “bus bar” that provides electrical
connection between all contact points on the terminal block (Figure 3-2).
Electrical
"Knock-Outs"
Bus Bar
Heater
Housing
End Cover (2X)
Terminal Blocks
Jumper Bars (6X)
The presence of the bus and jumper bars on each terminal block allows the heater to be
easily wired in different configurations. A model 4555 heater wired in a single-zone
configuration is shown in Figure 3-3. In this configuration the lamps mounted in the
Model 4555 all simultaneously receive the same voltage from the power source. In this
case, electrical connection from each terminal block to the power source is made by a
single, high temperature grade, electrical wire as follows:
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Model 4555 PanelIRTM User Manual Installation
Figure 3-3 Single Zone
Wiring
Figure 3-4 Single Zone
Single Phase
Schematic
480 V
SINGLE
PHASE
Heater
Incoming Power
Bus Bar
Terminal
Blocks
WARNING!
The electrical power required to operate the 4555 is extremely dangerous. Make sure
all electrical power that is to be provided to the Model 4555 is adequately turned off
prior to making any electrical connection to the heater.
NOTE:
The following instructions are for single-phase electrical wiring of the Model 4555. See
next section for three-phase wiring.
↔
↓
←
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Model 4555 PanelIRTM User Manual Installation
Single Phase Wiring
Prepare heater unit for wiring
Remove electrical connection
“knock-outs”
Install high temperature wire
Wiring Power to Heater
1. Remove the three screws from each of the end covers on each end of the heater
using the Phillips screwdriver.
2. Carefully remove each of the end covers and set them aside so that they are not
damaged.
1. Using the hammer and punch, remove one circular “knock-out” from each end of
the top of the heater by placing the metal punch on the knock-out outline and
striking the punch with the hammer until the knock-out protrudes into the heater.
2. Using the pliers, remove both knock-out slugs from the heater body.
3. Discard the knock-out slugs.
1. On each end, use the tape measure to measure the distance from the center of each
terminal block to the point at which the supply power and the high temperature
wire are to be joined.
2. Include additional length to account for wire travel through the knock-out hole and
enough to perform adequate wire stripping prior to attachment to the heater and
power supply wiring.
3. Cut two lengths of high temperature wire corresponding to the measured lengths.
4. Strip the insulation from each end of each wire to expose the conductor material
(approximately ½”)
5. Feed one wire (each) into the heater through each end of the heater between the
terminal blocks and the back of the heater and up through the knock-out hole.
Install the wires into the terminal blocks (see Figure 3-4).
6. If the amp draw is 50 amps or less, the stripped end of the wire can be inserted
directly into the terminal block. If it is greater than 50 amps, attach a ring lug to the
end of the wire and install the ring onto the bus bar with a screw and nut.
1. Attach the unconnected end of each high temperature wire to the power supply
wiring using appropriate wire joining techniques (as specified by local electrical
codes and standards).
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Model 4555 PanelIRTM User Manual Installation
Three Phase Wiring
Prepare heater unit for wiring
Remove electrical connection
“knock-outs”
Install high temperature wire
Wiring Power to Heater
1. Remove the three screws from each of the end covers on each end of the heater
using the Phillips screwdriver.
2. Carefully remove each of the end covers and set them aside so that they are not
damaged.
3. Remove the Bus Bars from the terminal blocks. Leave the jumper bars in place.
1. Using the hammer and punch, remove one circular “knock-out” from each end of
the top of the heater by placing the metal punch on the knock-out outline and
striking the punch with the hammer until the knock-out protrudes into the heater.
2. Using the pliers, remove both knock-out slugs from the heater body.
3. Discard the knock-out slugs.
1. On each end, use the tape measure to measure the distance from the center of each
terminal block to the point at which the supply power and the high temperature
wire are to be joined.
2. Include additional length to account for wire travel through the knock-out hole and
enough to perform adequate wire stripping prior to attachment to the heater and
power supply wiring.
3. Cut three lengths of high temperature wire corresponding to the measured lengths.
4. Strip the insulation from each end of each wire to expose the conductor material
(approximately ½”)
5. Feed one wire into the heater through one knock-out and two wires through the
other. Install the wires into the terminal blocks.
6. Jumper wires will need to be installed into the terminal blocks to complete the three
phase circuit (see Figure 3-5)
1. Attach the unconnected end of each high temperature wire to the power supply
wiring using appropriate wire joining techniques (as specified by local electrical
codes and standards).
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Model 4555 PanelIRTM User Manual Installation
Figure 3-5 Single Zone 3
Phase Wiring
Diagram
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Model 4555 PanelIRTM User Manual Installation
Multi-Zone Wiring
Prepare heater unit for wiring
Remove electrical connection
“knock-outs”
The Model 4555 can also be wired so that multiple heating zones are produced within
the heater. When configured for multi-zone operation, each zone of lamps is
electrically controlled by its own power control device. Wiring the Model 4555 for
multi-zone operation is as follows:
1. Remove the three screws from each of the end covers on each end of the heater
using the Phillips screwdriver.
2. Carefully remove each of the end covers and set them aside so that they are not
damaged.
1. Three knock-outs are provided on each end of the Model 4555. Multiple knock-
outs can be removed on each end of the heater so that an individual knock-out does
not have to accommodate more than three or four wires. It is left up to the installer
to determine the number of knock-outs to remove to simplify the wiring procedure.
2. Using the hammer and punch, remove one circular “knock-out” from each end of
the top of the heater by placing the metal punch on the knock-out outline and
striking the punch with the hammer until the knock-out protrudes into the heater.
3. Using the pliers, remove the knock-out slugs from the heater body.
4. Discard the knock-out slugs.
1. Using the slotted screwdriver, loosen the screws holding the bus bar in the terminal
blocks.
2. Lift the bus bar out of the terminal strip.
3. As shown in Figure 3-6, the bus and jumper bars can be cut to produce shorter,
individual jumpers corresponding to the number of desired heating zones. For
zones with more than 4 lamps, cut the bus bar the desired length. Use the jumper
bars for zones with 4 lamps or less. Move the plastic spacers so that they are
between the terminal blocks for each zone. They are required to insure electrical
isolation between zones.
4. Tighten each of the screws in the terminal blocks and jumper bars.
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