Chromalox Electric Heater DS 50600 User Manual

®
Chromalox  
DIVISION  
SALES  
SECTION  
4
VTS  
(Supersedes PG436-1)  
PG436-2  
REFERENCE  
161-304901-004  
DATE  
JUNE, 2010  
DS-50600, STAR-GF, STAR-TIP and STAR-TG Kits  
For Adding Optional Kits to STAR Radiant Heaters  
Model STAR-TIP  
STAR-TG  
STAR-GF  
Model DS50600  
Always check to make certain the voltage rating of the kit  
matches the voltage rating of the heater (See Nameplates).  
ELECTRIC SHOCK HAZARD. Disconnect all power  
to heater before installing or servicing kit(s).  
Failure to do so could result in personal injury or  
property damage. Kit(s) must be installed by a  
qualified person in accordance with the National  
Electrical Code, NFPA 70.  
GENERAL  
To use this instruction sheet from Table 1 select the Installation  
Instructions by matching the Kit Model to the Heater Model. If a  
match does not exist consult Factory.  
The kits are add-on options to STAR Radiant Heaters. The  
installation and renewal parts identification for the heater is cov-  
ered in the instruction sheet provided with the heater. SAVE  
BOTH COPIES OF THE INSTRUCTION SHEET.  
Table 1  
Kit Model  
DS-50600  
DS-50600  
STAR-GF  
STAR-TIP  
STAR-TG  
Used with Heater Model  
Fixed STAR-06A and STAR-14A  
Portable STAR-06A and STAR-14A  
All Fixed STAR  
Kit Function  
Installation Instructions Wiring Diagram  
Adds Integral Disconnect Switch  
Adds Integral Disconnect Switch  
See Page 2  
See Page 3  
Fig. 1  
Fig. 1  
Fig. 2  
Fig. 3  
Fig. 4  
Adds Wall Mounted Ground Fault Sensor  
Adds Tip Over Shut Down  
See Page 4  
Portable STAR-06A and STAR-14A  
Portable STAR-06A and STAR-14A  
See Page 5  
Adds Tip Over Shut Down with Ground Fault Sensor  
See Pages 5 and 6  
© 2008 Chromalox, Inc.  
 
INSTALLATION INSTRUCTIONS  
Cover  
(Step 5)  
3 Pole Disconnect Switch  
3 Pole Terminal Block w/Ground (Step 11)  
Chase Nipple and Gasket  
(Step 6)  
Self Tapping Screw  
(Step 8)  
On-Off Handle  
Opening for 1" Cord Fitting  
(Step 11)  
Cover  
(Step 3)  
Mounting Bracket  
(Step 4)  
3/8" Lockwasher and Nut  
(Step 4)  
Drawing shows 6 kW heater.  
13.5 kW heater steps are identical.  
INSTRUCTIONS FOR INSTALLING DISCONNECT SWITCH ON  
6 AND 13.5 KW PORTABLE RADIANT HEATERS  
1. Addition of the disconnect switch assy must be done by a qualified electrician.  
2. The disconnect switch kit includes the following parts.  
Verify that all parts are included, if not, contact the Chromalox Service Dept.  
(1)Disconnect Switch Assy  
(2)Mounting Bracket  
(3)Hardware Kit:  
Two 3/8” Lockwashers  
Two 3/8” Nuts  
One Self Tapping Screw  
One Gasket for Cord Fitting (Supplied Separately)  
3. Remove the screws in the heater terminal box. Remove cover.  
4. Place mounting bracket over 3/8” studs as shown. Place lockwashers on studs and secure in place  
with 3/8” nuts.  
5. Remove cover from disconnect switch assy using same method as Step 3.  
6. Remove Chase nipple and gasket from opening end of disconnect switch assy. Slide Chase nipple  
through hole in heater terminal box and then gasket over threads.  
7. Thread Chase nipple into threaded coupling. Hand tighten only.  
8. LIne up hole in bottom of disconnect switch housing with hole in mounting bracket. Tap 10-32 x  
1/2” long screw into mounting bracket.  
9. Wrench tighten Chase nipple installed in Step 6.  
10.Uncoil three (3) leads marked “1”, “2”, and “3” located in disconnect switch housing. Thread these  
three (3) leads through the nipple. Attach leads to the terminals indicated on the heater wiring label  
located on the cover of the heater. If using for single phase, cap off lead marked “3”.  
11.Attach cord assy to the opening in the disconnect switch housing. Connect leads of cord to termi-  
nal block.  
12.Inspect all wiring to make sure all connections are tight, adequate electrical clearances exist, and  
all electrical practices are met.  
13.Install both covers.  
3
 
INSTRUCTIONS FOR INSTALLING WALL MOUNTED STAR-GF  
STAR-GF Mounting Dimensions  
1. Check voltage on heater nameplate and STAR-GF to make cer-  
tain voltages are the same. If voltages do not match, consult  
factory.  
8-1/2"  
6"  
2. The STAR-GF will provide ground fault protection for STAR  
Radiant heaters. The number of heaters serviced by one (1)  
STAR-GF is dependent on the number and length of the heat-  
ing elements. See Table 2.  
3/4  
Table 2  
3. See Instruction Sheet PG434 (provided with heater) for  
Heater Model  
Max. No. of Heaters  
IMPORTANT INSTRUCTIONS and WIRING.  
STAR-02A  
STAR-05A  
STAR-06A  
STAR-14A  
6
3
2
1
4. Using the STAR-GF as a template mark mounting holes on  
wall. Use an anchoring method adequate to support the weight.  
5. Wire between STAR-GF and heater, wire to terminal block.  
Service entrance wiring to be made to contactor connectors.  
For wire gage see Table 1 of PG434.  
10-3/4"  
10"  
6. The ground fault sensor has been factory set at .03 Amps, DO  
NOT CHANGE THE SETTING.  
3/4  
5/16 Dia.  
6"  
MAINTENANCE  
The Chromalox STAR-GF ground fault sensor provides a reli-  
able and cost effective method for sensing ground faults. The pur-  
pose is to monitor for ground faults, sense potential heater failure  
symptoms and to protect equipment.  
Failure to do so could result in personal injury or  
property damage. Kit(s) must be installed by a  
qualified person in accordance with the National  
Electrical Code, NFPA 70.  
The current-carrying wires are routed through the current  
transformer on the control. When ground current reaches the level  
set by the trip point adjustment, (.03 Amps), the relay trips, illu-  
minates the tripped LED and provides an output signal which de-  
energizes the magnetic contactor.  
If heating element(s) fail to operate:  
1. Open door of enclosure. DANGER: Hazard of Electric  
Shock. If "Tripped" indicator is on, this indicates one or more  
heating elements are about to fail. Disconnect power and fol-  
low the GF Troubleshooting Diagram below.  
2. If the "Tripped" indicator is not on, check for blown fuses or  
failed components within the heater's electrical system.  
ELECTRIC SHOCK HAZARD. Disconnect all power  
to heater before installing or servicing kit(s).  
GF TROUBLESHOOTING DIAGRAM  
START  
Tripped Indicator  
Light is On  
Is this the  
initial  
No  
Yes  
This condition indicates  
at least one element is  
about to fail.  
installation?  
Did the problem  
Is this the first  
time heater is  
used for the  
season?  
occur after  
Is the set point of  
the GF sensor set  
at a value less than  
.03 amps?  
No  
Call Chromalox  
Service Dept.  
1 800-368-2493  
No  
working properly  
during part of this  
heating season?  
Yes  
Unbuss wiring, check insulation resistance  
Yes  
Yes  
on each element.  
Unbuss wiring, check insulation resistance  
on each element.  
1. Each element to have at least 10 Meg  
terminal to sheath.  
2. If element does not have at least 10 Meg.  
dry out element by applying half of the  
rated voltage for one hour.  
3. Rebuss elements, re-energize heater, flip  
toggle switch back and forth, one time  
to reset GF sensor.  
1. Each element to have at least 10 Meg  
terminal to sheath.  
2. If element does not have at least 10 Meg.  
dry out element by applying half of the  
rated voltage for one hour.  
3. Rebuss elements, re-energize heater, flip  
toggle switch back and forth, one time  
to reset GF sensor.  
1. Turn set point dial  
clockwise to .03 amps.  
2. Flip toggle switch mounted ontop  
of enclosure back and forth one  
time, (this resets the GF sensor).  
Do you want to  
reduce future  
down time and  
maintenance  
costs?  
No  
Yes  
No  
Does the heater  
operate?  
1. Replace all elements.  
2. Flip toggle switch back  
and forth, one time to  
reset GF sensor.  
Does the  
heater  
operate?  
No  
Yes  
Does the  
heater  
operate?  
No  
Close cover.  
Call Chromalox  
Service Dept.  
1 800-368-2493  
Yes  
No  
Does the heater  
operate?  
Yes  
Close cover.  
Close cover.  
Yes  
Close cover.  
4
 
INSTALLATION INSTRUCTIONS  
3 POLE CONTACTOR  
SELF TAPPING SCREW (STEP 8)  
HEAT/NO HEAT  
OPENING FOR 1" CORD FITTING (STEP 11)  
CHASE NIPPLE AND GASKET (STEP 6)  
MOUNTING BRACKET  
(STEP 4)  
COVER (STEP 3)  
3/8" LOCKWASHER AND NUT (STEP 4)  
VIEW SHOWN WITH TIP OVER SWITCH ASSY COVER REMOVED  
Drawing shows 6 kW heater.  
13.5 kW heater steps are identical.  
INSTRUCTIONS FOR INSTALLING “STAR-TIP” AND “STAR-TG” ON  
6 AND 13.5 KW PORTABLE RADIANT HEATERS  
1. Addition of the tip over switch assy must be done by a qualified electrician.  
2. The tip over switch assy includes the following parts.  
Verify that all parts are included, if not, contact the Chromalox Service Dept.  
(1)Tip Over Switch Assy  
(2)Mounting Bracket  
(3)Hardware Kit:  
Two 3/8” Lockwashers  
Two 3/8” Nuts  
Two Self Tapping Screw  
One Gasket for Cord Fitting (Supplied Separately)  
3. Remove the screws in the heater terminal box. Remove cover.  
4. Place mounting bracket over 3/8” studs as shown. Place lockwashers on studs and secure in place  
with 3/8” nuts.  
5. Remove cover from tip over switch assy using same method as Step 3.  
6. Remove Chase nipple and gasket from open end of tip over switch assy. Slide Chase nipple through  
hole in heater terminal box and then gasket over threads.  
7. Thread Chase nipple into threaded coupling. Hand tighten nipple.  
8. Line up hole in bottom of tip over switch with hole in mounting bracket. Tap 10-32 x 1/2” long  
screws into mounting bracket.  
9. Wrench tightened Chase nipple installed in Step 6.  
10.Uncoil three (3) leads marked “1”, “2”, and “3” located in disconnect switch housing. Thread these  
three (3) leads through the nipple. Wire nut leads of tip over switch to leads of heater. If using for  
single phase, cap off lead marked “3”.  
11.Attach cord assembly to the opening in the tip over switch housing. Connect leads of cord to the  
contactor.  
12.Inspect all wiring to make sure all connections are tight, adequate electrical clearances exist, and  
all electrical practices are met.  
13.Install both covers.  
5
 
MAINTENANCE  
The Chromalox STAR-TG tip over cutout with ground fault  
Failure to do so could result in personal injury or  
property damage. Kit(s) must be installed by a  
qualified person in accordance with the National  
Electrical Code, NFPA 70.  
sensor provides a reliable and cost effective method for sensing  
ground faults and to shut off the heater in case of tip-over. The pur-  
pose of the ground fault control is to monitor for ground faults,  
sense potential heater failure symptoms and to protect equipment.  
The current-carrying wires are routed through the current  
transformer on the control. When ground current reaches the level  
set by the trip point adjustment, (.03 amps), the relay trips, illumi-  
nates the tripped LED and provides an output signal which de-  
energizes the magnetic contactor.  
If heating element(s) fail to operate:  
1. Open door of enclosure. DANGER: Hazard of Electric  
Shock.  
2. If "Tripped" indicator is not on, check for blown fuses or failed  
electrical components in the heater’s electrical system includ-  
ing the tip over trip mechanism.then this indicates one or more  
heating elements are about to fail.  
3. Check pendulums on the tip over switch mechanisms to be sure  
they are not blocked.  
4. If the "Tripped" indicator is on, then this indicates one or more  
heating elements are about to fail. Disconnect power and fol-  
low the GF Troubleshooting Diagram below.  
ELECTRIC SHOCK HAZARD. Disconnect all power  
to heater before installing or servicing kit(s).  
TG TROUBLESHOOTING DIAGRAM  
START  
Tripped Indicator  
Light is On  
Is this the  
initial  
No  
Yes  
This condition indicates  
at least one element is  
about to fail.  
installation?  
Did the problem  
Is this the first  
time heater is  
used for the  
season?  
occur after  
Is the set point of  
the GF sensor set  
at a value less than  
.03 amps?  
No  
Call Chromalox  
Service Dept.  
1 800-368-2493  
No  
working properly  
during part of this  
heating season?  
Yes  
Unbuss wiring, check insulation resistance  
Yes  
Yes  
on each element.  
Unbuss wiring, check insulation resistance  
on each element.  
1. Each element to have at least 10 Meg  
terminal to sheath.  
2. If element does not have at least 10 Meg.  
dry out element by applying half of the  
rated voltage for one hour.  
3. Rebuss elements, re-energize heater, flip  
toggle switch back and forth, one time  
to reset GF sensor.  
1. Each element to have at least 10 Meg  
terminal to sheath.  
2. If element does not have at least 10 Meg.  
dry out element by applying half of the  
rated voltage for one hour.  
3. Rebuss elements, re-energize heater, flip  
toggle switch back and forth, one time  
to reset GF sensor.  
1. Turn set point dial  
clockwise to .03 amps.  
2. Flip toggle switch mounted ontop  
of enclosure back and forth one  
time, (this resets the GF sensor).  
Do you want to  
reduce future  
down time and  
maintenance  
costs?  
No  
Yes  
No  
Does the heater  
operate?  
1. Replace all elements.  
2. Flip toggle switch back  
and forth, one time to  
reset GF sensor.  
Does the  
heater  
operate?  
No  
Yes  
Does the  
heater  
operate?  
No  
Close cover.  
Call Chromalox  
Service Dept.  
1 800-368-2493  
Yes  
No  
Does the heater  
operate?  
Yes  
Close all covers.  
Close all covers.  
Yes  
Close all covers.  
6
 
WIRING  
For applicable wiring diagram see Table 1  
TERMINAL BLOCK  
TOGGLE  
SWITCH  
TIPOVER  
SWITCH  
NOTES:  
GRN L1 L2  
L3  
1. USE 90 DEG. C. MIN. WIRING.  
TIPOVER  
SWITCH  
4
3
6
5
2. USE COPPER CONDUCTORS ONLY.  
3. TO MAINTAIN THE ENVIRONMENTAL  
RATING OF THIS ENCLOSURE, USE  
ONLY UL LISTED OR RECOGNIZED  
LIQUID TIGHT CONDUIT HUBS.  
2
CONTACTOR  
1
3
2
1
L3  
L2  
L1  
NOTES:  
1. USE 90 DEG. C. MIN. WIRING.  
DISCONNECT  
SWITCH  
2. USE COPPER CONDUCTORS ONLY.  
3. VERIFY THAT VOLTAGE OF "STAR-TIP"  
MATCHES VOLTAGE OF HEATER.  
3
2
1
TO TERMINALS  
INSIDE HEATER  
JUNCTION BOX  
TO TERMINALS  
INSIDE HEATER  
JUNCTION BOX  
PRI. SIDE TRANSFORMER CONNECTION:  
208V = BLK AND RED  
Fig. 1  
240V = BLK AND ORG  
277V = BLK AND BRN  
BLACK  
WHITE  
380V = BLK AND VIOLET  
480V = BLK AND BLK/RED  
600V = BLK AND GRAY  
TRANSFORMER  
UNUSED LEADS CAPPED OFF.  
Fig. 3  
GROUND FAULT  
MONITOR  
TOGGLE SWITCH  
SUPPLY  
G
3
2
1
NC  
CO  
TO TERMINALS  
INSIDE HEATER  
JUNCTION BOX  
NO  
CONTACTOR  
L3  
L2  
L1  
SEE NOTES  
POWER LEADS MUST  
PASS THROUGH CURRENT  
TRANSFORMER POSITION  
OF GROUND FAULT  
MONITOR  
ATTACHED TO  
AUXILLARY TERMINALS  
PRI. SIDE TRANSFORMER CONNECTION:  
208V = BLK AND RED  
240V = BLK AND ORG  
NOTES:  
1. USE 90 DEG. C. MIN. WIRING.  
277V = BLK AND BRN  
2. USE COPPER CONDUCTORS ONLY.  
3. VERIFY THAT VOLTAGE OF "STAR-TG"  
MATCHES VOLTAGE OF HEATER.  
380V = BLK AND VIOLET  
480V = BLK AND BLK/RED  
600V = BLK AND GRAY  
UNUSED LEADS CAPPED OFF.  
WHITE  
BLACK  
TRANSFORMER  
Fig. 2  
GROUND FAULT  
MONITOR  
TOGGLE  
SWITCH  
TIPOVER  
SWITCH  
TIPOVER  
SWITCH  
3
2
1
SUPPLY  
NC  
NO  
CO  
TO TERMINALS  
INSIDE HEATER  
JUNCTION BOX  
CONTACTOR  
L3  
L2  
L1  
POWER LEADS MUST  
PASS THROUGH CURRENT  
TRANSFORMER POSITION  
OF GROUND FAULT  
MONITOR  
SEE NOTES  
ATTACHED TO  
AUXILLARY  
TERMINALS  
PRI. SIDE TRANSFORMER CONNECTION:  
208V = BLK AND RED  
240V = BLK AND ORG  
277V = BLK AND BRN  
NOTES:  
1. USE 90 DEG. C. MIN. WIRING.  
480V = BLK AND BLK/RED  
380V = BLK AND VIOLET  
600V = BLK AND GRAY  
2. USE COPPER CONDUCTORS ONLY.  
3. VERIFY THAT VOLTAGE OF "STAR-TG"  
MATCHES VOLTAGE OF HEATER.  
UNUSED LEADS CAPPED OFF.  
WHITE  
BLACK  
TRANSFORMER  
Fig. 4  
7
 
RENEWAL PARTS IDENTIFICATION  
Kit  
Model  
Disconnect  
Switch  
DS Shaft  
Gasket  
Cover  
Gasket  
“U” Shaped  
Clamp  
Term. Block  
Cont. Sect.  
Term. Block  
End. Sect.  
Toggle  
Switch  
Toggle Switch  
Boot  
Ground Fault  
Sensor  
Tip Over  
Switch  
Contactor  
DS-506008 292-303472-007 132-304689-001 132-304879-002 056-304884-004  
NA  
NA  
NA  
NA  
NA  
STAR-GF-8  
STAR-GF-3  
STAR-GF-4  
STAR-GF-7  
STAR-GF-6  
STAR-TIP-8  
STAR-TIP-2  
072-121651-062  
STAR-TIP-3  
STAR-TIP-4  
STAR-TIP-7  
STAR-TIP-6  
STAR-TG-8  
STAR-TG-2  
STAR-TG-3  
STAR-TG-4  
STAR-TG-7  
STAR-TG-6  
NA  
NA  
NA  
NA  
303-052241-002 303-052241-001 292-046123-001 024-052539-001 072-306110-008  
N/A  
292-304695-001  
072-121651-062  
Limited Warranty:  
Please refer to the Chromalox limited warranty applicable to this product at  
2150 N. RULON WHITE BLVD., OGDEN, UT 84404  
TA - T0 - EF  
Litho in U.S.A.  
Phone: 1-800-368-2493  
 

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