Chromalox KDS-1 Switch User Manual

SERVICE REFERENCE
4
DIVISION
SECTION
SALES
REFERENCE
®
KUH
(Supersedes PF486-2)
PF486-3
161-303476-001
DATE
AUGUST, 2004
INSTALLATION INSTRUCTIONS AND RENEWAL PARTS IDENTIFICATION
Power Disconnect Switch Kits
Specifications – Table A
Electrical Data (60Hz)
Model
KUH-C-02-81
KUH-C-02-21
KUH-C-02-71
KUH-C-04-81
KUH-C-04-83
KUH-C-04-21
KUH-C-04-23
KUH-C-04-71
KUH-C-04-43
KUH-C-05-81
KUH-C-05-83
KUH-C-05-21
KUH-C-05-23
KUH-C-05-71
KUH-C-05-43
KUH-C-07-81
KUH-C-07-83
KUH-C-07-21
KUH-C-07-23
KUH-C-07-71
KUH-C-07-43
KUH-C-10-81
KUH-C-10-83
KUH-C-10-21
KUH-C-10-23
KUH-C-10-43
KUH-C-12-83
KUH-C-12-23
KUH-C-12-43
KUH-C-15-83
KUH-C-15-23
KUH-C-15-43
KUH-C-20-23
KUH-C-20-43
KUH-C-25-43
KUH-C-30-83
KUH-C-30-23
KUH-C-30-43
KUH-C-35-23
KUH-C-35-43
KUH-C-40-23
KUH-C-40-43
KUH-C-45-43
3 Pole
Model
KDS-1
Rating
50 Amp for units rated 480V and less
40 Amp for units rated 500V to 600V
PCN
304434
Power Disconnect Switch
for Field Installation
3 Pole 600 V Rating
Model
KDS-2
KDS-3
Rating
80 Amp
100 Amp
PCN
304442
304450
Volts
kW
Phase
Amps
208
208/240
277
2.667
2/2.667
2.667
208
4
208/240
3/4
277
480
4
4
208
5
208/240
3.75/5
277
480
5
5
208
7.5
208/240
5.625/7.5
277
480
7.5
7.5
208
10
208/240
7.5/10
480
208
208/240
480
208
208/240
480
208/240
480
480
208
208/240
480
208/240
480
208/240
480
480
10
12.5
9.375/12.5
12.5
15
11.25/15
15
15/20
20
25
30
22.5/30
30
26.25/35
35
30/40
40
45
1
1
1
1
3
1
3
1
3
1
3
1
3
1
3
1
3
1
3
1
3
1
3
1
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
12.8
11.1*
9.6
19.2
11.2
16.7*
9.6*
14.5
4.8
24.0
13.8
20.8*
12.1*
18.2
6.0
36.1
20.9
31.1*
18.1*
27.2
9.0
48.0
27.8
41.7*
24.0*
12.0
34.8
30.1*
15.1
41.8
36.2*
18.1
48.0*
24.0
30.0
83.4
72.2*
36.1
84.3*
42.1
96.0*
48.0
54.1
Standard
Contactor
Rating (Qty.)
30A (1)
30A (1)
30A (1)
30A (1)
30A (1)
30A (1)
50A (1)
30A (1)
30A (1)
30A (1)
30A (1)
30A (1)
50A (1)
30A (1)
30A (1)
30A (1)
30A (1)
50A (1)
50A (1)
30A (1)
50A (1)
50A (1)
30A (1)
50A (1)
30A (1)
50A (1)
50A (2)
50A (2)
30A (2)
50A (2)
30A (2)
50A (2)
30A (2)
30A (2)
*208V amperage is 86% of 240V value.
GENERAL
The following procedure contains instructions for installing
Power Disconnect Switches.
© 2010 Chromalox®, Inc.
ELECTRIC SHOCK HAZARD. Disconnect all power
before installing disconnect switch. Failure to do
so could result in personal injury or property damage. 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 1
Knockout
Figure 2
Mounting Plate Cover
(4) 8-18 x 1/2
Figure 5
(4) 8-32 x 1/2
(4) 8-18 X 1/2 SCREWS
Handle (2) 6-20 x 1/2
Pigtail Leads
Faceplate
COVER PLATE
Figure 3
40 and 50 Amp Kits — KDS-1
The disconnect switch has a bracket for mounting the switch.
REAR CASE
(4) 8-32 SCREWS
Mounting Bracket
Disconnect Switch
Plastic
Bezel
MOUNT SWITCH ASSEMBLY
ONTO REAR CASE OF HEATER
REAR CASE
(2) 6-20 x 1/2 SCREWS
Mounting Plate
Hardware
(Self Tapping)
MOUNT FACEPLATE WITH "ON"
POSITION TO TOP OF HEATER
Mounting Plate
Cover
1
Figure 4
80 and 100 Amp Kit — KDS-2 and KDS-3
The disconnect switch has a bracket for mounting the switch.
0
(OFF)
Figure 6 – KDS-1
2
(ON)
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
Switch Assembly Mounted to Rear Case
Figure 8
(4) 8-32 Screws
Snap Plastic Housing
Into Place
Cover Plate
Rear Case
Rear Case
Mount Switch Assembly
Onto Rear Case of Heater
Figure 9
Figure 7
WIRING
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” position (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.
ELECTRIC SHOCK HAZARD. Disconnect all power
before installing disconnect switch. Failure to do
so could result in personal injury or property damage. Disconnect switch must be installed by a
qualified person and must be effectively grounded
in accordance with the National Electrical Code,
NFPA 70.
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 disconnect 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.
Pigtail
Leads
Power
Disconnect
Switch
To
Power
Supply
For future replacement parts, the model number should be modified on the nameplate to show that a disconnect kit has been field
installed on the heater. A label kit (see Figure 14) (P/N 170302788-002) has been included in the plastic envelope located in
the disconnect kit. Cut off the appropriate number for the size disconnect being installed (40 Amp = 1; 80 Amp = 2; 100 Amp = 3).
The label has a pressure sensitive adhesive back so that the number can be placed over the “0” as shown in Figure 14.
Power
Disconnect
Switch
Contactor
L1
AL1
L2
AL2
L3
AL3
To
Power
Supply
See Notes
Contactor (1)
L1
AL1
L2
AL2
L3
AL3
See
Note 2
Notes:
1. This illustration shows wiring hook up for three phase
service. Remove lead wires marked L2 and AL2 when
using one phase power service.
Contactor (2)
2. For units without contactors, disconnect switch is to
be wired to lead wires on heater power.
KUH-30 through KUH-45 units with 2 contactors
where the total load does not exceed 48 Amps.
3. Use copper supply wire only with this switch.
Figure 10
KUH-02 through KUH-25
Power Disconnect Switch
Figure 11
3
WIRING (Cont’d)
Fuse Block (1)
Contactor (1)
Fuse Block (2)
Contactor (2)
Power
Disconnect
Switch
To
Power
Supply
L1
AL1
L2
AL2
L3
AL3
KUH-30 through KUH-45 units with 2 contactors
where the total load exceeds 48 Amp and subcircuit fuse blocks are provided.
Figure 12
®
-42 -43 -44 -45 -1
-2
-3
Place Number at
the end of the
Catalog Number
CATALOG NO.
KUH-C- 07 - 43 - 32 - 00 - 0
DATE
MFG. PART NO. 004 - 303375 - 265
CODE
MIN. CIRC. CAP.
AMPS MAX. CIRC. FUSE
RATING
KW
V.A.C. ONLY
PH
AMPS
Number 1, 2 or 3 designates the Disconnect Code for Kit.
1 = 40 Amp; 2 = 80 Amp; 3 = 100 Amp
HEATER
MOTOR
CONT. CKT.
7.5
480V
3
9.0
480V
120V
1
1
.28
10
SERIAL NO.
AMPS
HZ
60
V.A.
MAX.
60
60
P/N 196-057744-002
Figure 14 — Nameplate
Figure 13 — Pressure Sensitive Label
REPLACEMENT PARTS LIST
Disconnect
Size
Kit Model #
Disconnect
Cover Plate
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
http://www.chromalox.com/customer-service/policies/termsofsale.aspx.
Mounting Bracket