Chromalox HVH-TK5 User manual

The following procedure contains instructions for installing ther-
mostat kits HVH-TK5 and HVH-TK6 in HVH-02 through HVH-
15 Heaters.
ELECTRIC SHOCK HAZARD. Disconnect all power
before installing thermostat kit. Failure to do so
could result in personal injury or property damage.
Thermostat kit must be installed by a qualified per-
son in accordance with the National Electrical Code,
NFPA 70.
© 2010 Chromalox, Inc.
Thermostat Kits
Model Number HVH-TK5
Model Number HVH-TK6
For field installation only in HVH-02 through HVH-15 heaters
SPECIFICATIONS
1. Temperature Range: 40˚F to 90˚F.
2. Differential: 5˚F.
3. Non-inductive Rating:
120V @ 25 Amperes
240V @ 25 Amperes
277V @ 22 Amperes
(Supersedes PF448-6)
PF204-1
LUH
161-305676-001
JANUARY, 2007
4
RENEWAL PARTS IDENTIFICATION
Installation, Operation
and
DATE
SALES
REFERENCE
DIVISION SECTION
Chromalox
®
LO HI
OFF
Chromalox
R
GENERAL
INSTALLATION
Step 1
1. Verify that the thermostat kit is compatible with your heater.
HVH-TK-6 is a DPST line voltage thermostat, it can be used
on 1Ø, 240V max. up to 25A and 1Ø, 277V up to 22A heaters.
HVH-TK-5 is a SPST is a thermostat used in conjunction with
a contactor.
2. Peel off “Chromalox” label located on the bottom front corner
of the heater. Removal of the label will reveal the holes for
mounting the thermostat (See Figure 1).
3. Carefully remove the KO on the bottom side of heater.
KO
Nameplate
Figure 1

INSTALLATION (cont’d.)
Step 2 (Figure 2)
1. Remove (2) screws on cover and open cover.
2. Feed thermostat capillary (be careful not to kink or make any
sharp bends) out through the hole made in step 1.
3. Mount body of thermostat to front of heater case using the (2)
6-32 flat head screws (not location of leadwires shown in illus-
tration). Attach new label and knob provided with TK kit.
Step 3 (Figure 3)
1. Attach thermostat bulb to case using the (2) clamps and
screws.
2. Make a slit in the rubber grommet and insert the grommet over
the capillary.
3. Install the grommet into the hole in the case.
Step 4
1. For TK-6 Thermostat kits, wire one blue lead of thermostat to
terminal block pole “L1” and the other blue lead to terminal
block pole “L2”. Connect incoming power wiring to the black
leads with wire nuts provided by others. See figure 4 for line
voltage thermostat. See figure 8 for control voltage thermostat.
For TK-5 thermostat kits with an internally provided control
circuit, remove white jumper wire on terminal block between
poles “C1” and “C2”. Connect blue wire of thermostat to pole
“C1” and black wire to “C2”. See figures 5, 6 or 7.
For TK-5 thermostat kits with an externally provided control
circuit, remove white jumper wire on terminal block between
poles “C2” and “C3”. Connect blue wire of thermostat to pole
“C2” and black wire to “C3”. See figure 7.
2. Inspect wiring to make sure it matches the appropriate wiring
diagram.
3. Close heater cover and reattach screws.
SHEET METAL
SCREW
CLAMP
THERMOSTAT
BULB
KNOB
LABEL FOR
THERMOSTAT
6-32 FLAT
HEAD
SCREW
THERMOSTAT
BODY
RUBBER
GROMMET
LEADWIRES
Figure 2
Figure 3
}
Motor
Blue
Blue
Optional Thermostat
Built in or field installed
Optional Disconnect Switch
Built in or field installed
Power
60 Hz
Elements
1Ø Element Wiring
(Omit for 2 Element
Heaters)
Cutout
Terminal
Block
T1 T3
T2
L1 L3
L2
Black
Black
Figure 4
208-277V 1Ø — 2.6 & 5 kW
WIRING DIAGRAMS

TO T1
TO T1
TO T2
TO T3
TO T3
TO T2
{
TRANSFORMER COLOR CODE INDEX
VOLT LEAD CLRS LEAD CLRS LEAD CLRS
X2
BLU
BLU
BLU
BLU
BLU
X2
WHT
WHT
WHT
WHT
WHT
H2
RED
OR
BR
BLK/RED
GRA YELBLKBLK575
YELBLKBLK480
YELBLKBLK277
YELBLKBLK240
YELBLKBLK208
X1X1H1
24V SEC.
120V SEC.
PRI. XFMR
PRI.
Motor
Optional Thermostat
Built in or field installed
Elements
3Ø Wiring
Terminal
Block
T1 T3
T2
L1 L3
L2 Pink
C1 C2 C3
1Ø Wiring
To T1 To T1 To T1
To T2 To T2 To T2
NOTE:
1. Omit "L3" wiring for 1Ø heaters
2. 3Ø Motorsused on all 480V, 7.5 kW or higher
heaters. All other heatersuse 1Ø motors.
See Note #2
Optional Disconnect
Switch Built in or
field installed
Sec
X1 X2
H1 H2
Power 60 Hz
Remove jumper wire when
themostat isused
Figure 5
208-277V 1Ø or 3Ø with contactor
WIRING DIAGRAMS (cont’d.)
TO T1
TO T1
TO T2
TO T3
TO T3
TO T2
{
Motor
Orange
Purple
Optional Thermostat
Built in or field installed
Optional Disconnect
Switch Built in or
field installed
Power
60 Hz
Elements
3Ø Wiring
Cutout
Terminal
Block
T1 T3
T2
L1 L3
L2 Pink
C1 C2 C3
1Ø Wiring
To T1 To T1 To T1
To T2 To T2 To T2
NOTE: Omit "L3" wiring for 1Ø heaters
Remove jumper wire when thermostat isused
Figure 7
1Ø or 3Ø with optional external 24
or 120V control using single
pole thermostat
Remove jumper wire when
thermostat isused
TO T1
TO T1
TO T2
TO T3
TO T3
TO T2
{
{
Motor
Optional Thermostat Built in or field installed
Elements
3Ø Wiring
Terminal
Block
T1 T3
T2
L1 L3
L2
C1 C2 C3
1Ø Wiring
To T1 To T1 To T1
To T2 To T2 To T2
NOTE:
1. Omit "L3" wiring for 1Ø heaters
Optional Disconnect
Switch Built in or
field installed
Power 60 Hz
Externally provided control voltage.
See nameplate for voltage
Cutout
Figure 6
208-480V 1Ø or 3Ø
with contactor and transformer

HVH-TK-5 Components KiT HVH-TK-6 Components Kit
Part Number* Part Number*
Thermostat 300-049197-003 300-049197-004
Screws248-049282-021 (2) 248-049282-021 (2)
Rubber Grommet 135-075436-008135-075436-008
Label Decal 170-049279-016 170-049279-016
Bulb Clip 059-075500-002 059-075500-002
Knob 169-049278-001 169-049278-001
*Number in Parentheses ( ) indicates the quantity of that part required.
2150 N. RULON WHITE BLVD., OGDEN, UT 84404
Phone: [phone] www.chromalox.com
TA - U0 - EF
Litho in U.S.A.
RENEWAL PARTS IDENTIFICATION
RENEWAL PARTS IDENTIFICATION
Figure 8
1Ø or 3Ø with optional external 24
or 120V control using double
pole thermostat
TO T1
TO T1
TO T2
TO T3
TO T3
TO T2
{
{
Remove jumper wire when
thermostat isused
Motor
Elements
3Ø Wiring
Terminal
Block
T1 T3
T2
L1 L3
L2
C1 C2 C3
1Ø Wiring
To T1 To T1 To T1
To T2 To T2 To T2
Optional
Disconnect
Switch Built
in or field
installed Power
60 Hz
Optional Double
Pole Thermostat
Cutout
Externally Provided Control Voltage.
See Nameplate for Voltage.
NOTE:
1. Omit "L3" wiring for 1Ø heaters
Limited Warranty:
Please refer to the Chromalox limited warranty applicable to thisproduct at
http://www.chromalox.com/customer-service/policies/termsofsale.aspx.