Danfoss KPU 61 User manual

Installation guide
Thermostat
Type KPU
© Danfoss A/S (AC-MC / jmn), 2014-02 DKRCC.PI.CD0.A3.22 / 520H8467 1
060R9769 060R9769
Application
KPU thermostats are used for regulation and to ensure safety
in refrigeration, freezing, air conditioning, ventilating and
heating systems.
KPU thermostats are available with vapor charge or with
adsorption charge.
All KPU thermostats are tted with Single-Pole Double-Throw
(SPDT) switches.
For large a.c. motors and for all d.c. motors, KPU is installed
in the control circuit. For single phase ac motors, KPU
is installed in the line voltage supply to the motor.
The standard KPU enclosure is rated NEMA 1.
NEMA 1 is obtained when the thermostat is mounted on a at
surface. When mounting KPU on a bracket, cover all unused
holes.
Product Specication
Thermostat bulb types
Charge Type Code no. Bulb type
Capillary tube
length Reset
function
Regulating
range Dierential Δt Max. bulb temperature
Ambient
temperature
[in.] [°F] [°F] [°F] [°F]
Vapor
KPU 61 060L5201 A80 auto. -20 – 60 4 – 18 2) 250
-40 – 122
(170 for max.
2 hours)
KPU 61 060L5203 B80 auto. -20 – 60 4 – 18 2) 250
KPU 61B 060L5204 B80 man. (min.) 1) -20 – 60 5 (xed) 2) 250
KPU 61B 060L5205 B200 man. (min.) 1) -20 – 60 5 (xed) 2) 250
KPU 61 060L5210 B80 auto. -20 – 60 4 – 18 2) 250
KPU 62 060L5206 C1 0auto. -20 – 60 4 – 18 2) 250
KPU 63 060L5213 A80 auto. -60 – 15 10 – 25 2) 250
KPU 63 060L5214 B80 auto. -60 – 15 10 – 25 2) 250
KPU 68 060L5215 C1 0auto. 25 – 95 5 – 22 2) 250
KPU 69 060L5217 B80 auto. 25 – 95 5 – 22 2) 250
Adsorption
KPU 62 060L5207 C2 0auto. -20 – 60 4 – 15 175
KPU 73 060L5208 E3 80 auto. -15 – 60 5 – 35 175
KPU 73 060L5209 E1 80 auto. -15 – 60 15 – 45 175
KPU 73B 060L5211 E3 80 man. (min.) 1) -15 – 60 6 (xed) 175
KPU 73 060L5212 D80 auto. -15 – 60 5 – 35 175
KPU 71 060L5218 E2 80 auto. 25 – 70 5 – 18 175
KPU 71B 060L5216 E2 80 man. (min.) 1) 25 – 70 5 (xed) 175
KPU 74 060L5219 E1 80 auto. 0 – 80 9 – 35 175
KPU 74B 060L5220 E1 80 man. (min.) 1) 0 – 80 10 (xed) 175
KPU 75 060L5221 F80 auto. 30 – 95 5 – 18 230
KPU 77 060L5223 E3 80 auto. 60 – 140 6 – 18 265
1) man. (min.): Manual reset after cut-out on falling temperature.
2) The switch dierential is dependent on range settings. Low range settings increases the dierential.
High range settings decreases the dierential. Use the graphs on page 3 to determine the correct dierential setting.
A B C D E F
straight capillary tube remote air coil air coil/room sensor double contact remote coil remote bulb remote duct coil

Screws for
bracket
mounting
Mounting holes
for at surfaces
2 DKRCC.PI.CD0.A3.22 / 520H8467 © Danfoss A/S (AC-MC / jmn), 2014-02
Installation
Select an accessible location, where the thermostat will not
be subject to damage. Mount the KPU on a bracket or on a
completely at surface. Mounting on an uneven surface may
cause incorrect thermostat operation. For bracket mounting,
use only the 10-32 x
3
/
16
in. screws furnished with the
thermostat. Other screws may interfere with the functioning of
the thermostat. In no case can screws protrude more than
1
/
8
in. into the thermostat. Use only the mounting holes provided.
Do not make additional holes.
IMPORTANT:
For vapor charged thermostats, ensure that the bulb
is installed in a colder location than the thermostat
housing and capillary tube. This prevents charge
migration from the bulb and ambient temperature
will have no eect on regulation accuracy.
For adsorption charged thermostats, the bulb can be placed
in a warmer or colder location than the thermostat housing
and capillary tube.
General recommendations for capillary tube
and bulb installation:
1. Protect the capillary tube from damage due to vibration.
a) When the thermostat unit is mounted directly on the
compressor, the capillary tube must be secured to the
compressor so that both vibrate together.
b) For mounting otherwise, form surplus capillary tube
into a loose loop, and secure the length of capillary tube
between the compressor and the loop to the compressor.
Secure the length from the loop to the thermostat to the
base on which the thermostat is mounted.
2. Leave a little slack in the capillary tube to help dampen
vibration.
3. Avoid sharp bends and bending the capillary tube at the
same point several times, as these actions can weaken the
material and increase the likelihood of the tube cracking.
4. Form and locate the capillary tube away from sharp or
abrasive objects that might damage it.
5. Never allow the capillary tube of a vapor charged
thermostat to run alongside of a suction line in a wall entry.
6. Ensure minimal length of capillary tube exposed to
temperature for KPU with straight capillary bulb type:
− 16 in. for KPU tharmostats with 80 in.
capillary tube,
− 22 in. for KPU thermostats with 200 in.
capillary tube.
7. For thermostats with room sensor coils, make sure that
placement allows free airow around the coil and bulb.
At the same time, ensure that the bulb is not exposed to
drafts from doors, or to heat radiated from the evaporator
surface. Make sure that the bulb does not come into
contact with a wall surface. Never mount the thermostat
directly on a cold wall. Instead, mount the unit on an
insulating plate.
IMPORTANT:
Do not dent or deform the bulb of the thermostat, as
doing so could damage the bulb and cause charge
leakage.
Wiring
Electrical ratings according to UL regulations
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
European electrical ratings according to EN 60947
AC1 AC3 AC15 LR DC13
16 A 16 A 10 A 112 A 12 W
400 V 220 V
CAUTION:
To avoid the possibility of electric shock and damage
to equipment, diconnect the power supply before any
wiring connections are made. Never touch current
conducting (LIVE) parts with your ngers or with tools.
NOTE:
All wiring should conform to the National Electrical
Code and to applicable local regulations. Use only
copper wire. Use only the terminal screws furnished in
the terminal block. Do not exceed tightening torque
of 20 inch pounds (2.3 Nm). Do not exceed the
thermostat’s specied electrical ratings.
The terminal block as well as grounding screw are accessible
after dismounting the front cover.

LOAD ~ LINE LOAD ~ LINE
A
© Danfoss A/S (AC-MC / jmn), 2014-02 DKRCC.PI.CD0.A3.22 / 520H8467 3
Wire dimensions: 10 AWG max.
Cable entry: 7/8in. cable entry for 1/2in. male pipe thread
connection (conduit boss) or similar (Pg 13.5 or Pg 16 )
screwed cable entry.
Contact function test (Manual trip)
When the electrical leads are connected the contact function
can be manually tested regardless of temperature conditions
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 thermostat.
NOTE:
While operating the manual trip on KPU switches with
manual reset it is necessary to push the reset knob.
A: Manual trip. Push the lever. Use ngers only!
B: Manual reset button (only on versions sold with manual
reset function)
C: Terminal block
D: Grounding screw
Wiring Option A:
– Cut-Out on temperature fall
Wiring Option B:
– Cut-Out on temperature rise
°C °F
KPU 61
KPU 62
°C
°F LSP
B
C
°F
D
°C
KPU 63
LSP
°C
°F LSP
KPU 68
KPU 69
°C °F
°C °F
15
10
0
10
20
30 70
15 °F
Dierential lines
Dierential lines
130
020 40 60 80 100 120
90 80 70 60 50 40 30 20 15
110 90 70 50 30 10 10
55 50 40 30 20 10 010 20
50 30 10 10 30 50 70
10
20
30
40
50
35
25
15
5
0
5
60
40
20
0
20
20
0
20
40
60
100
80
60
40
20
20
25 20 10 010 20 30 40 50
20 °F
30 °F
20 °F
15 °F
5 °F
20 °F
10 °F
10 °F
5 °F
Dierential lines
HSP
HSP
HSP
Determination of dierential
For KPU thermostats with vapor charge and automatic reset,
use the following graphs to determine the correct dierential.
Example:
HSP = 45 °F DIFF (from graph):
LSP = 32 °F => 13 °F (value which has to be set on di. scale)

A
D
E
B
C
manual switch
1.
2.
1.
Adjustment
NOTE:
Adjust the tharmostat to settings specied by the
manufacturer of the controlled equipment. When
checking thermostat operation, or operating
the controlled equipment, do not exceed the
manufacturer’s temperature ratings for the controlled
equipment or for any of its components.
To avoid inaccurate thermostat operation, do not
adjust the KPU’s pointers beyond the highest or lowest
indicator marks on the scale plate.
Before adjustment loosen the locking screw.
For setting use Universal Refrigeration Wrench or the setting
knob, if available. Movement of the setting knob is limited
by the locking screw, which allows only small corrections to
the settings. Therefore, if the setting knob is to be used for
adjustments, completely remove the locking screw. After
adjustment, tighten the locking screw.
Manual switch
Available only on KPU 61 (060L5210) and KPU 62 (060L5207),
the manual switch is a two-position switch used to shut down
the refrigeration system. The two positions are:
1. AUTO: position for automatic operation.
2. STOP: contacts 1 and 2 are locked in the closed position.
CAUTION:
The manual switch only stops automatic operation,
and can only be used for service on non-electrical
parts. Interrupt mains power before servicing
electrical parts.
Adjustment: thermostat with automatic reset
Scale plate directly indicates High Switching Point
and Dierential.
Adjustment: thermostat with manual reset
Scale plate directly indicates Low Switching Point, which is
Cut-Out. There is no pointer for Dierential.
Dierential value is xed and printed on the scale plate.
1. Set High Switching Point 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 Dierential.
3. Low Switching Point is equal
to High Switching
Point less Dierential:
LOW = HIGH - DIFFERENTIAL
1. Set Cut-Out (Low Switching Point)
by adjusting range screw. Turn
the screw clockwise to lower
the set point.
2. High Switching Point (Cut-In)
equals Low Switching Point
(Cut-Out) plus Dierential:
CUT IN = CUT OUT + DIFFERENTIAL
IMPORTANT:
The scale plate is only for reference and for more
precise setting a temperature gauge should be used.
IMPORTANT:
After installing and adjusting the thermostat, check
your settings by running the controlled equipment
several times (at least three times) under normal
operating conditions.
A: Setting knob
B: Locking screw
C: Range adjusting screw
D: Dierential adjusting screw
E: Cover screw
4 DKRCC.PI.CD0.A3.22 / 520H8467 © Danfoss A/S (AC-MC / jmn), 2014-02