Chromalox PK405-18 Thermostat User Manual
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Chromalox ® Installation Instructions and RENEWAL PARTS IDENTIFICATION SERVICE REFERENCE 4 DIVISION SALES REFERENCE AR SECTION PK405-18 (Supersedes PK405-17) 161-049287-001 DATE MARCH, 2004 AR (Single Phase) Industrial Thermostat Table A – Specifications Sensing Bulb NEMA I Model* 3-3/8” 3-1/8” Temperature Range (˚F) 0–100˚F Style Dia. (In.) Approx. Length (In.) 5 0.375 4-3/8 AR-115 AR-115A 5-7/8” 2 12 AR-214 7 AR-214D AR-215A 60–250˚F AR-219 AR-219D AR-514 AR-515 AR-515A 200–550˚F AR-519 AR-519D AR-715 AR-715D Maximum A.C. Rating (Amps.) 7 AR-115C AR-215 NEMA-I Model Capillary Length (Ft.) 300–700˚F AR-719 4 0.250 5-5/32 5 0.375 4 9 0.188 10-3/4 4 0.250 7-5/16 5 0.375 3-5/8 9 0.188 11-1/2 5 0.375 3-11/16 9 0.188 12 10 Amp. 480 Vac 30 Amp. 120-277 Vac 15 7 2 250VA 120-277 Vac (Pilot Duty) 7 15 7 7 2 7 15 7 15 7 *Models equipped with Pilot Light are designated by the suffix “P” on the Model Number. Models equipped with Knob Cover are designated by the suffix “KC” on the Model Number. Models equipped with both a Pilot Light and a Knob Cover are designated by the suffix “PKC” on the Model Number. Models installed in a moisture resistant enclosure are designated by the suffix “LT” on the Model Number. Pilot Light nor Knob Cover available on LT models. 2-21/32" CL 7/8” 7/8” 3/4” NPT Conduit Holes 4-3/32" 7-1/16” 2-21/32" . Typ .D. 2" O pillary Ca 4-7/16” AR-LT 5-1/16” Moisture Resistant Model Length Figure 1 © 2010 Chromalox, Inc. Bulb Dia. (Refer to Specifications Table A) GENERAL NOTICE: Type AR Thermostats are designed for temperature control service only. Because they do not fail safe, they should not be used for temperature limiting duty. The system designer is responsible for the safety of this equipment and should install adequate back-up controls and safety devices with their electric heating equipment. Where the consequences of failure could result in personal injury or property damage, back-up controls are essential. Principle of Operation – Control action of these thermostats is provided through the principle of liquid volume change. With a variation in temperature, the liquid in the sensing bulb expands or contracts, causing a bellows to actuate the switching mechanism. Enclosure – The control enclosure and cover assembly is of heavygauge electrical grade plastic on NEMA-I models. Moisture resistant (LT) models have enclosure and cover assembly made of heavy gauge cast aluminum. Power Supply – FIRE/ELECTRIC SHOCK HAZARD. Use AC supply only. Thermostat is not DC rated. Control Range – The following temperature ranges are available: 0° to 100°F 200° to 550°F 60° to 250°F 300° to 700°F Process Temperature Differential – is variation in controlled process temperature between maximum, when thermostat turns OFF and minimum, when thermostat turns ON. This spread in temperature may be minimized by: 1. Making sure control is mounted to vertical surface (see Step 1, Mounting section). 2. Avoiding excess heating capacity (oversized heaters). 3. Locating control sensing bulb in optimum position between heat source and work. In general, it is difficult to predict the actual operating differential of a given process. Temperature differential may be as low as 4˚F for low range controls to as high as 17˚F for higher range controls since the differential is a percentage function of the dial range. Packing Glands – If a sealed or leak-proof connection is required at the point where the capillary enters the oven, tank, pipe or similar equipment, an appropriate packing gland is available as an optional part. (Model Numbers CCF-25A, CCF-25D or CCF-25E). FIRE/EXPLOSION HAZARD. This thermostat is not intended for use in hazardous atmospheres where flammable vapors, gases, liquids or other combustible atmospheres are present as defined in the National Electrical Code. Failure to comply can result in personal injury or property damage. MOUNTING Note: Do not mount control where it will be subject to vibration, shock, grease, dust, lint or corrosive vapors. Do not mount adjacent to a large magnetic contactor, as vibration and shock will cause thermostat to interact erratically - resulting in chattering of the contactor. The air temperature in and around the control enclosure should be kept as near to normal room temperature as possible...never above 150°F. NEMA-I Models LT Models 2-7/16" Dia. 4. CAUTION – A. Bending or deforming sensing bulb will alter control calibration – requiring recalibration after installation. See CALIBRATION section, page 3. If necessary, Style 9 bulbs can be coiled to 1” I.D. (see Figure 3). B. Do not kink capillary tube. The resulting constrictions in fluid flow can destroy control function or broaden temperature differential. Minimum capillary tube bending diameter is 1/2” I.D. (see Figure 4). 1” Figure 3 (Sensing Bulb) 5" 3-7/8" Dia. Do Not Bend or Kink Crimped End 5/16" Dia. Mounting Holes 7/32" Dia. Mounting Lugs (4) 5-7/8" Dia. (2) 1/2” Rod 1. To facilitate adjusting and reading the thermostat, knob setting must be mounted in a vertical position only. 2. Use sheet metal or wood screws through the mounting holes in baseplate to mount control (see Figure 2). 3. For controlling platen or die temperatures, insert entire sensing bulb into drilled holes selected for snug slip fit. The longer, more sensitive Style 9 bulbs should be used for controlling air temperatures or pipe line heating. Note: If material in contact with bulb or capillary is corrosive, a protective well should be used. Protective wells are available as an optional part. Check factory. Figure 4 (Capillary Tube) C. Any deformations of bulb or capillary that result in leakage of fluid from control renders control inoperative. D. Avoid passing control capillary tube through zones whose temperature is in excess of controlled process temperature. Erratic control or destruction of control function may result. WIRING ELECTRIC SHOCK HAZARD. Disconect all power to heater before installing or servicing thermostat. Failure to do so could result in personal injury or property damage. Thermostat must be installed by a qualified person in accordance with the National Electrical Code, NFPA 70. 1. Electrical wiring must be installed in accordance with National Electrical Codes or local codes. CAUTION: Use copper conductors only. NEMA-I Models – A. Entrance for wiring is provided by two 1/2” conduit holes in end of base plate. B. If control is a “–KC” model (knob cover), remove knob cover as in Figure 5. C. Set thermostat knob to OFF position and then remove knob by lifting knob from shaft (see Figure 6). D. Loosen two screws from end of base plate and remove thermostat cover (see Figure 7). WIRING Figure 7 Figure 6 Figure 5 LT Models – A. Entrance for wiring is provided by two 3/4” NPT conduit holes in end of enclosure. Wiring to control enclosure should be in moisture-resistant conduit. B. Remove cover by removing four hexhead screwbolts (see Figures 8 and 9). 2. Connect wires according to wiring diagrams (Figure 11 thru 15). Figure 8 Figure 9 Note: Electrical connections should be made with generous loops of wire – approximately 6” per lead. 3. Replace cover and tighten screws. 4. Replace dial knob and dial knob cover. (NEMA-I models only). 5. Note: If load amperage or voltage rating exceeds switch rating, a contactor must be used (see Figure 14). Contactors are available as an optional part. Pilot Pilot Light Light Pilot Light Load 1 Load 2 Line 1 1 2 3 3 4 2 Line 3 4 4 Load Single Phase Load Figure 11 Figure 12 Line Single Phase Line Figure 13 Two Circuit Line 1 2 3 Control Voltage 4 Pilot Light Figure 14 Three Phase When Load Does Not Exceed Rating of Thermostat. Three Phase And Single Phase When Load Exceeds Rating of Thermostat. Load Pilot Light 1 2 3 4 } Line Figure 15 WIRING C Screwdriver Thermometer B Adjusting Shaft A Adjusting Set Screw Load (Tank, vat, die or platen) Figure 16 Figure 17 ELECTRIC SHOCK HAZARD. Disconnect all power before attempting to calibrate thermostat. Failure to comply could result in personal injury. These controls are factory calibrated to the range indicated on the control adjustment knob. If calibration is required, either one of two methods may be followed: A. If accurate measurement standards are not available, the thermostat can be readily adjusted to a known temperature standard such as boiling water (212˚F) (see Figure 16). B. With the aid of an accurate thermometer or other temperature measuring device, recalibration may be performed within the process as in Figure 17. For either method, the following general calibration procedures should be followed: 1. Remove knob cover, knob and thermostat housing as per instructions 3, 4 and 5 under WIRING. Figure 18 2. Replace knob and turn to highest temperature setting. 3. Slowly turn knob and when controls click “off”, compare the dial reading against the thermometer reading. 4. If they do not agree – A. Set dial knob to thermometer temperature reading and pull off knob. B. While holding the adjusting shaft (B) tightly, turn small center adjusting screw (A) with small screwdriver (C) until thermostat clicks “off” (see Figure 18). Note: Always use extreme care not to damage the slot in the center adjusting screw. C. Each quarter turn of the screw will change the calibration approximately 30˚F: – Clockwise to decrease temperature – Counterclockwise to increase temperature D. Recheck calibration and repeat process if closer calibration is required. RENEWAL PARTS IDENTIFICATION LT-Models NEMA-I Models 3 2 1 4 080-510512-001 152-025660-004 Enclosure 027-057548-001 Mounting Bracket 213-018509-002 119-114623-003 Pack Gland Model 1 2 3 4 Thermostat Sub-Assembly Thermostat Cover Thermostat Base Knob AR-115 300-048518-005 080-024763-001 015-013819-001 169-019605-002 AR-115A 300-048518-012 080-024763-001 015-013819-001 169-019605-002 AR-115C 300-048518-019 080-024763-001 015-013819-001 169-019605-002 AR-214 300-048518-001 080-024763-001 015-013819-001 169-019604-001 AR-214D 300-048518-026 080-024763-001 015-013819-001 169-019604-001 AR-215 300-048518-010 080-024763-001 015-013819-001 169-019604-001 AR-215A 300-048518-013 080-024763-001 015-013819-001 169-019604-001 AR-219 300-048518-002 080-024763-001 015-013819-001 169-019604-001 AR-219D 300-048518-022 080-024763-001 015-013819-001 169-019604-001 AR-514 300-048518-003 080-024763-001 015-013819-001 169-019604-002 AR-515 300-048518-011 080-024763-001 015-013819-001 169-019604-002 AR-515A 300-048518-014 080-024763-001 015-013819-001 169-019604-002 AR-519 300-048518-004 080-024763-001 015-013819-001 169-019604-002 AR-519D 300-048518-027 080-024763-001 015-013819-001 169-019604-002 AR-715 300-048518-006 080-024763-001 015-013819-001 169-019605-001 AR-715D 300-048518-029 080-024763-001 015-013819-001 169-019605-001 AR-719 300-048518-007 080-024763-001 015-013819-001 169-019605-001 Limited Warranty: Please refer to the Chromalox limited warranty applicable to this product at http://www.chromalox.com/customer-service/policies/termsofsale.aspx. 1347 HEIL QUAKER BLVD., LAVERGNE, TN 37086 Phone: (615) 793-3900 www.chromalox.com
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