HEATFLO KUH-C-02-71 (01) PDF MANUAL


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PDF Content Summary: © 2010 Chromalox®, Inc. DIVISION SERVICE REFERENCE 4 SECTION KUH ® SALES REFERENCE (Supersedes PF486-2) PF486-3 161-303476-001 DATEAUGUST, 2004 INSTALLATION INSTRUCTIONS AND RENEWAL PARTS IDENTIFICATION Power Disconnect Switch Kits Specifications – Table A Electrical Data (60Hz) Standard Model Volts kW Phase Amps Rating Contactor (Qty.) KUH-C-02-81 208 2.667 1 12.8 KUH-C-02-21 208/240 2/2.667 1 11.1* KUH-C-02-71 277 2.667 1 9.6 KUH-C-04-81 KUH-C-04-83 208 4 1 19.2 3 11.2 30A (1) KUH-C-04-21 KUH-C-04-23 208/240 3/4 1 16.7* 3 9.6* 30A (1) KUH-C-04-71 277 4 1 14.5 KUH-C-04-43 480 4 3 4.8 30A (1) KUH-C-05-81 KUH-C-05-83 208 5 1 24.0 3 13.8 30A (1) KUH-C-05-21 KUH-C-05-23 208/240 3.75/5 1 20.8* 3 12.1* 30A (1) KUH-C-05-71 277 5 1 18.2 KUH-C-05-43 480 5 3 6.0 30A (1) 3 Pole Model Rating PCN KDS-1 50 Amp for units rated 480V and less 304434 40 Amp for units rated 500V to 600V KUH-C-07-81 KUH-C-07-83 208 7.5 1 36.1 50A (1) 3 20.9 30A (1) KUH-C-07-21 KUH-C-07-23 208/240 5.625/7.5 1 3 31.1* 18.1* 30A (1) 30A (1) KUH-C-07-71 277 7.5 1 27.2 30A (1) KUH-C-07-43 480 7.5 3 9.0 30A (1) KUH-C-10-81 KUH-C-10-83 208 10 1 48.0 50A (1) 3 27.8 30A (1) KUH-C-10-21 KUH-C-10-23 208/240 7.5/10 1 41.7* 30A (1) 3 24.0* 30A (1) KUH-C-10-43 480 10 3 12.0 30A (1) KUH-C-12-83 208 12.5 3 34.8 50A (1) KUH-C-12-23 208/240 9.375/12.5 3 30.1* 50A (1) KUH-C-12-43 480 12.5 3 15.1 30A (1) KUH-C-15-83 208 15 3 41.8 50A (1) KUH-C-15-23 208/240 11.25/15 3 36.2* 50A (1) Power Disconnect Switch KUH-C-15-43 480 15 3 18.1 30A (1) for Field Installation KUH-C-20-23 208/240 15/20 3 48.0* 50A (1) KUH-C-20-43 480 20 3 24.0 30A (1) KUH-C-25-43 480 25 3 30.0 50A (1) KUH-C-30-83 208 30 3 83.4 50A (2) KUH-C-30-23 208/240 22.5/30 3 72.2* 50A (2) KUH-C-30-43 480 30 3 36.1 30A (2) KUH-C-35-23 208/240 26.25/35 3 84.3* 50A (2) KUH-C-35-43 480 35 3 42.1 30A (2) 3 Pole 600 V Rating KUH-C-40-23 208/240 30/40 3 96.0* 50A (2) KUH-C-40-43 480 40 3 48.0 30A (2) Model Rating PCN KUH-C-45-43 480 45 3 54.1 30A (2) KDS-2 80 Amp 304442 *208V amperage is 86% of 240V value. KDS-3 100 Amp 304450 GENERAL The following procedure contains instructions for installing Power Disconnect Switches. ELECTRIC SHOCK HAZARD. Disconnect all power before installing disconnect switch. Failure to do so could result in personal injury or property dam- age. Disconnect switch must be installed by a qualified person in accordance with the National Electrical Code, NFPA 70. INSTALLATION 1. The amperage rating of the disconnect must be equal to or greater than the amperage rating on Table A and as marked on the nameplate located on the bottom access door (Figure 1). 2. The power disconnect kit is to be installed in the rectangular knockout located in the bottom right corner on the back of the heater (Figure 2). The knockout can be removed using a hammer and chisel or other appropriate means. For easier access to terminal screws to wire pigtail leads supplied on the heater, it is suggested that these connections be made before installing. See Wiring Instructions. 3. The disconnect switch assembly (Figures 3 or 4) consists of a mounting bracket, disconnect switch, mounting plate cover and self tapping screws. 4. The Disconnect switch, with its mount-ing bracket should be inserted into the heater cabinet by opening the bottom service door and positioned behind the opening created in Step 2 (see Figure 5). KDS–1 5. The disconnect switch, with its mounting plate should be inserted into the heater cabinet by opening the bottom service door and positioned behind the opening created in step 2 (see Figure 5). 6. Insert the four self tapping screws into the four holes in the rear panel. They should engage the holes in the mounting plate and then be tightened until they are secure (see Figure 6). 7. Mount the switch faceplate to the switch using the two provided screws. Mount with the “OFF” position to “0” to the left and the on position “1” to the top. Slide the handle over the shaft and tighten the screw to secure. Figure 2 Mounting Plate Cover (4) 8-18 x 1/2 (4) 8-32 x 1/2Handle (2) 6-20 x 1/2 Faceplate Pigtail Leads Figure 4 80 and 100 Amp Kit — KDS-2 and KDS-3 The disconnect switch has a bracket for mounting the switch. 2 Figure 1 Figure 3 40 and 50 Amp Kits — KDS-1 The disconnect switch has a bracket for mounting the switch. Mounting Bracket Disconnect Switch Plastic Bezel Mounting Plate Hardware (Self Tapping) Mounting Plate Cover Knockout (4) 8-18 X 1/2 SCREWS COVER PLATE REAR CASE REAR CASE 0 Figure 6 – KDS-1 (4) 8-32 SCREWS MOUNT SWITCH ASSEMBLY ONTO REAR CASE OF HEATER (2) 6-20 x 1/2 SCREWS MOUNT FACEPLATE WITH "ON" POSITION TO TOP OF HEATER Figure 5 1 (ON) (OFF) INSTALLATION (Cont’d) KDS–2 and KDS – 3 8. The cover plate should be placed over the rectangular opening with its four mounting holes lined up with the four holes in the cabinet and the four holes in the mounting bracket (see Figure 7). 9. Insert the four self tapping screws into the four holes until they engage the holes in the mounting bracket and tighten until they are secure (see Figure 8). 10. Place plastic bezel over the installed switch and push towards the switch until the tabs snap into place (see Figure 9). Rear Case POWER DISCONNECT SWITCH (Available as a kit or factory installed option.) (KDS-1)This switch disconnects the power to power leads when the handle is rotated to the “0” posi- tion (left). The power is on when the switch handle is rotated to the “1” position (top) position. (KDS-2 and KDS-3) This switch disconnects power to the power leads when the handle is placed in its full lower position. The power is on when the switch handle is in its full upper position. 1. Use the three pigtail leads supplied with kit (40 & 80 Amp) when connecting to the power line. a. Use No. 4GA Copper conductor wire only for 100 Amp dis- connect when wiring to the power line. 2. The power disconnect wiring to the heater is to be made using the pigtail leads supplied on the heaters up to and including 25 kW. On larger heaters, the installer should supply 105 ̊C type AWM 600V wire. Rear Case Switch Assembly Mounted to Rear Case Rear Case Figure 8 (4) 8-32 Screws Cover Plate Snap Plastic Housing Into Place Mount Switch Assembly Onto Rear Case of Heater Figure 7 Figure 9 WIRING 3 ELECTRIC SHOCK HAZARD. Disconnect all power before installing disconnect switch. Failure to do so could result in personal injury or property dam- age. Disconnect switch must be installed by a qualified person and must be effectively grounded in accordance with the National Electrical Code, NFPA 70. For future replacement parts, the model number should be modi- fied on the nameplate to show that a disconnect kit has been field installed on the heater. A label kit (see Figure 14) (P/N 170- 302788-002) has been included in the plastic envelope located in the disconnect kit. Cut off the appropriate number for the size dis- connect being installed (40 Amp = 1; 80 Amp = 2; 100 Amp = 3). The label has a pressure sensitive adhesive back so that the num- ber can be placed over the “0” as shown in Figure 14. Power Disconnect Pigtail Leads Switch Contactor L1L2L3 Power Disconnect Switch Contactor (1) ToPower Supply L1AL1 AL1 L2AL2 See Notes ToPower AL2 L3 AL3 Supply AL3 See Note 2 Notes: 1. This illustration shows wiring hook up for three phase service. Remove lead wires marked L2 and AL2 when Contactor (2) using one phase power service. 2. For units without contactors, disconnect switch is to be wired to lead wires on heater power. 3. Use copper supply wire only with this switch. KUH-30 through KUH-45 units with 2 contactors Figure 10 where the total load does not exceed 48 Amps. KUH-02 through KUH-25 Power Disconnect Switch Figure 11 WIRING (Cont’d) Fuse Block (1) Contactor (1) Power Disconnect Switch L1AL1 ToPower L2AL2 Supply L3 AL3 Fuse Block (2) Contactor (2) KUH-30 through KUH-45 units with 2 contactors where the total load exceeds 48 Amp and sub- circuit fuse blocks are provided. Figure 12 -42 -43 -44 -45 -1 -2 -3 ® Place Number at CATALOG NO. KUH-C- 07 - 43 - 32 - 00 - 0 MFG. PART NO. 004 - 303375 - 265 DATE CODE Disconnect Size Kit Model # Disconnect Cover Plate Mounting Bracket 50 Amp KDS-1 292-303472-001 220-303485-010 80 Amp KDS-2 292-303472-002 220-303485-003 220-303484-003 100 Amp KDS-3 292-303472-008 220-303485-003 220-303484-003 Limited Warranty: Please refer to the Chromalox limited warranty applicable to this product at chromalox.com/customer-service/policies/termsofsale.aspx. the end of the Catalog Number MIN. CIRC. CAP. AMPS MAX. CIRC. FUSE AMPS Number 1, 2 or 3 designates the Disconnect Code for Kit. RATING KW V.A.C. ONLY PH AMPS HZ 1 = 40 Amp; 2 = 80 Amp; 3 = 100 Amp HEATER 7.5 480V 3 9.0 60 MOTOR 480V 1 .28 60 CONT. CKT. 120V 1 10 V.A. MAX. 60 SERIAL NO. P/N 196-057744-002 Figure 13 — Pressure Sensitive Label Figure 14 — Nameplate REPLACEMENT PARTS LIST


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