Chromalox PK405-18 Thermostat User Manual

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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