Danfoss KPU 1 User manual

Installation Guide
Single Pressure Control
Type KPU
© Danfoss A/S (AC-MCI / jmn), 2012-12 DKRCC.PI.CD0.F1.22 / 520H6076 1
060R9767 060R9767
Application
KPU pressure controls are for use on commercial
refrigeration and air conditioning systems to give protection
against excessively low suction pressure or excessively
high discharge pressure.
They are also used for starting and stopping refrigeration
compressors and fans on air-cooled condensers.
KPU pressure controls are tted with the Single-Pole Single-
Throw (SPST) or Single-Pole Double-Throw (SPDT) switches,
suitable for direct as well as indirect (with a contactor) control.
KPU pressure controls are available in several pressure ranges
and are compatible with HCFC and non-ammable HFC
refrigerants. KPU 6W and KPU 6B are fail safe controls for high
pressure refrigerants (R410A and R744). Standard enclosure is
~NEMA 1
Installation
Select an accessible location, where the control and pressure
connection line will not be subject to damage.
IMPORTANT:
Mount the pressure control in a position that will
allow drainage of liquids away from control bellows.
Pressure connection of the control must always be
located on the top side of the refrigerant line.
This reduces the possibility of oil, liquids, or
sediment collecting in the bellows, which could
cause the control malfunction.
IMPORTANT:
Ensure the ambient temperature for the pressure
control is higher than the refrigeration line as that
will prevent liquid migration and accumulation in
the bellows.
Product Specication
Application Type
Code number
Reset
Contact system Regulating
range
[inHg]
[psig]
Dierential
∆p
[psi]
Max.
working
pressure
[psig]
Max.
testing
pressure
[psig]
Ambient
temp.
[°F]
¼ in.
male are
36 in. cap.
tube w. ¼ in.
are nut
Type Switch
action
Low Pressure
Control
Cut Out on
pressure fall
KPU 1 060-5231 060-5233 Auto. SPDT —6 in. – 108 10 – 60 250 290
-40 – 122
(175 for max.
2 hours)
KPU 1 060-5236 —Auto. SPST(NO) close High open Low 6 in. – 108 10 – 60 250 290
KPU 2 060-5237 060-5235 Auto. SPST(NO) close High open Low 6 in. – 73 6 – 30 250 290
KPU 2 060-5239 060-5240 Auto. SPDT —6 in. – 73 6 – 30 250 290
KPU1B 060-5232 060-5234 Man (Min.) SPDT —28 in. – 100 10 xed 250 290
Fan control KPU 5 060-5241 060-5242 Auto. SPST(NO) close High open Low 100 – 465 25 – 85 510 530
High Pressure
Control
Cut Out on
pressure rise
KPU 6W 060-5243 060-5245 Auto. SPDT —100 – 600 58 – 145 675 / 610* 725
KPU 6B 060-5244 060-5246 Man. (Max.) SPDT —100 – 600 60 xed 675 / 610* 725
* 610psig - MWP for products used according to 97/23/EG PED directive.

2 DKRCC.PI.CD0.F1.22 / 520H6076 © Danfoss A/S (AC-MCI / jmn), 2012-12
Mount the KPU pressure control on a bracket
or on a completely at surface.
Mounting to an uneven surface might cause
improper control operation.
For bracket mounting use only the 10-32x3/16
screws provided with the control. If other screws
are used function of the pressure control might be
disturbed (they may not protrude into the control
more than 1/8in.).
Use only the mounting holes provided;
no other holes are to be added to the control
IMPORTANT:
Pressure pulsations in the refrigeration system
reduce life time of the bellows and might
disturb switch function. Pressure pulsations
should always be eectively damped e.g.
by connection the pressure controls to the
refrigeration system through a capillary tube.
Screws for bracket
mounting
Mounting holes
for at surfaces
1. Ensure self-draining of the capillary tube
to minimize clogging.
2. Coil excess capillary tube into smooth, circular coils
(approximately 3 in. diameter). The coiled tube should
be securely fastened in order to prevent possible
damage due to vibration.
3. Leave a little slack in the capillary tube as it helps
to damp mechanical vibrations.
4. Avoid sharp bends as well as re-bending of the capillary
tube on the same point as it weakens the material,
increasing the risk of crack.
5. Never allow for contact between the capillary tube
and sharp or abrasive objects as during vibrations
the tube could be damaged due to friction.
6. Purge the piping before connecting pressure controls.
7. Always use two wrenches
tightening the are nut on
the pressure control.
One wrench should support
the connector while
the second wrench
is used to tighten the nut.
8. Do not over tighten are nuts as it may damage the
threadscausing leaks.
9. Protect the capillary tube from damage
caused by vibrations from compressor:
– when the control unit is mounted directly on the
compressor, the capillary must be secured to the
compressor so that everything vibrates as a whole.
– when the control is mounted remote from the
compressor, make the pressure connections away
from the compressor.
– when the control is mounted remote from the
compressor and the pressure connections have to be
on the compressor, then damping coils must be used
between the compressor and the pressure control.
NOTE:
After installing the pressure control, evacuate
the plant in accordance with applicable EPA
and other regulations, to remove air, moisture,
and other contaminants.
Recommendations for capillary tube and are connections:
Wiring CAUTION:
Disconnect power supply before wiring connections
are made or service to avoid possible electrical shock
or damage to equipment. Do never touch live parts
with your ngers or with any tool.
NOTE:
All wiring should conform to the National Electrical
Code and local regulations. Use copper wire only.
Use terminal screws furnished in the contact block.
Do not exceed tightening torque 20 lb. in (2.3 Nm).
Do not exceed electrical ratings for the control.
Electrical ratings according to UL regulations
European electrical ratings according to EN 60947
120 V a.c. 24 FLA, 144 LRA – make only
240 V a.c. 24 FLA, 144 LRA – make only
240 V d.c. 12 W pilot duty
The terminal block as well as grounding screw
are accessible after dismounting of the front cover.
AC1 AC3 AC15 LR DC13
16 A 16 A 10 A 112 A 12 W
400 V 220 V

Load ~Line Load ~Line
B
C
A
C
D
A
B
D
© Danfoss A/S (AC-MCI / jmn), 2012-12 DKRCC.PI.CD0.F1.22 / 520H6076 3
Wiring Option A:
– Low Pressure Control Cut Out on pressure fall
– Condenser Fan Cycling
Contact function test (Manual trip)
When the electrical leads are connected the contact function
can be manually tested regardless of pressure condition in
the system. The manual trip lever is located in the left side
of the KPU. It must be operated with ngers only. Do not use
screwdriver as it will damage the control.
Wiring Option B:
– High Pressure Control Cut Out on pressure rise
Wire dimensions: 10 AWG max.
Cable entry: 7/8in. cable entry for ½ in. male pipe thread connection
(conduit boss) or similar (Pg13.5 or Pg16) screwed cable entry.
NOTE:
While operating the manual trip on KPU
controls with manual reset it is necessary
to push the reset knob.
NOTE:
Adjust the pressure control with settings specied
by the manufacturer of the controlled quipment.
Do not exceed the pressure ratings of the controlled
equipment or any of its components when checking
pressure control operation or operating the
controlled equipment.
Do not adjust pointers beyond the highest or lowest
indicator marks on the scale plate, as this may cause
inaccurate control operation.
A: Manual trip. Press the lever up. USE FINGERS ONLY!
B: Manual reset button
(available only for contols with manual reset function)
C: Terminal block
D: Grounding screw
A: Dierential adjusting screw
B: Locking plate
C: Range adjusting screw
D: Cover screw
Adjustment
Before adjustment, loosen the locking plate.
For setting use the Universal Refrigeration Wrench.

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4 DKRCC.PI.CD0.F1.22 / 520H6076 © Danfoss A/S (AC-MCI / jmn), 2012-12
IMPORTANT:
The scale plate is only for reference
and for more precise setting
a pressure gauge should be used.
IMPORTANT:
After installing and adjusting pressure control run
the controlled equipment several times
(at least three cycles) at normal operating conditions.
Adjustment:
Low Pressure Control
Cut out on pressure fall
with automatic reset.
Scale plate directly indicates
the Cut In and the Dierential
set points.
1. Set Cut In by adjusting range screw.
Turn the screw clockwise to lower the set point.
2. Then set Dierential by adjusting dierential screw.
Turn the screw clockwise to increase the Dierential.
3. The Cut Out setting equals the Cut In
less the Dierential: CUT OUT = CUT IN - DIFFERENTIAL
NOTE:
Cut Out set point must be above absolute vacuum!
If the Dierential is set too high then the control
will not stop the compressor.
Adjustment:
Condenser Fan Cycling
Scale plate directly indicates
the Cut In and the Dierential
set points. 1. Set Cut In by adjusting range screw.
Turn the screw clockwise to lower the set point.
2. Then set Dierential by adjusting dierential screw.
Turn the screw clockwise to increase the Dierential.
3.The Cut Out setting equals the Cut In less
the Dierential: CUT OUT = CUT IN - DIFFERENTIAL
Adjustment:
Low Pressure Control
Cut out on pressure fall
with manual reset.
Scale plate directly indicates the Cut
Out set point. There is no
pointer for the Dierential.
The Dierential pressure value is xed
and printed on the scale plate.
1. Set Cut Out by adjusting range screw.
Turn the screw clockwise to lower the set point.
2. The Cut In setting equals the Cut Out plus
the Dierential: CUT IN = CUT OUT + 10 psi
Adjustment:
High Pressure Control
Cut Out on pressure
rise with automatic reset.
Scale plate directly indicates
the Cut Out and the Dierential
set points.
1. Set Cut Out by adjusting range screw.
Turn the screw clockwise to lower the set point.
2. Then set Dierential by adjusting dierential screw.
Turn the screw clockwise to decrease the Dierential.
3. The Cut In setting equals the Cut Out
less the Dierential: CUT IN = CUT OUT - DIFFERENTIAL
Adjustment:
High Pressure Control
Cut Out on pressure
rise with manual reset.
Scale plate directly indicates
the Cut Out set point.
There is no pointer for the Dierential.
The Dierential pressure value is xed
and printed on the scale plate.
1. Set Cut Out by adjusting range screw.
Turn the screw clockwise to lower the set point.
2. The Cut In setting equals the Cut Out
less the Dierential: CUT IN = CUT OUT - 60 psi