SERVICE REFERENCE
DIVISION
SALES
4
SECTION KUH
®
(Supersedes PF486-2)
161-303476-001
PF486-3
REFERENCE
DATE
AUGUST, 2004
INSTALLATION INSTRUCTIONS AND RENEWAL PARTS IDENTIFICATION
Power Disconnect Switch Kits
Specifications – Table A
Electrical Data (60Hz)
Standard
Contactor
Rating (Qty.)
Model
Volts
kW
Phase Amps
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
208
208/240
277
2.667
2/2.667
2.667
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
208
4
30A (1)
30A (1)
30A (1)
30A (1)
30A (1)
208/240
3/4
277
480
4
4
208
5
208/240
3.75/5
277
480
5
5
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)
3 Pole
208
7.5
Model
Rating
PCN
208/240
5.625/7.5
KDS-1 50 Amp for units rated 480V and less 304434
40 Amp for units rated 500V to 600V
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
Power Disconnect Switch
for Field Installation
3 Pole 600 V Rating
Model
KDS-2
KDS-3
Rating
80 Amp
100 Amp
PCN
304442
304450
*208V amperage is 86% of 240V value.
GENERAL
The following procedure contains instructions for installing
Power Disconnect Switches.
ELECTRIC SHOCK HAZARD. Disconnect all power
before installing disconnect switch. Failure to do
so could result in personal injury or property dam-
age. Disconnect switch must be installed by a
qualified person in accordance with the National
Electrical Code, NFPA 70.
© 2010 Chromalox®, Inc.
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INSTALLATION (Cont’d)
KDS–2 and KDS – 3
Rear Case
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).
Switch Assembly Mounted to Rear Case
Figure 8
Snap Plastic Housing
Into Place
(4) 8-32 Screws
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” posi-
tion (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 dam-
age. 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.
For future replacement parts, the model number should be modi-
fied on the nameplate to show that a disconnect kit has been field
installed on the heater. A label kit (see Figure 14) (P/N 170-
302788-002) has been included in the plastic envelope located in
the disconnect kit. Cut off the appropriate number for the size dis-
connect being installed (40 Amp = 1; 80 Amp = 2; 100 Amp = 3).
The label has a pressure sensitive adhesive back so that the num-
ber can be placed over the “0” as shown in Figure 14.
a. Use No. 4GA Copper conductor wire only for 100 Amp dis-
connect 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
Power
Power
Leads
Disconnect
Switch
Disconnect
Contactor
Switch
Contactor (1)
L1
L2
L3
AL1
AL2
AL3
L1
L2
L3
AL1
AL2
AL3
To
To
Power
Supply
Power
Supply
See Notes
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
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3
WIRING (Cont’d)
Fuse Block (1)
Contactor (1)
Power
Disconnect
Switch
L1
L2
L3
AL1
To
Power
Supply
AL2
AL3
Fuse Block (2)
Contactor (2)
KUH-30 through KUH-45 units with 2 contactors
where the total load exceeds 48 Amp and sub-
circuit fuse blocks are provided.
Figure 12
®
Place Number at
the end of the
Catalog Number
-42 -43 -44 -45 -1 -2 -3
CATALOG NO.
KUH-C- 07 - 43 - 32 - 00 - 0
004 - 303375 - 265
DATE
CODE
MFG. PART NO.
MIN. CIRC. CAP.
RATING
AMPS MAX. CIRC. FUSE
AMPS
KW
7.5
V.A.C. ONLY
480V
PH
3
AMPS
9.0
HZ
60
60
60
Number 1, 2 or 3 designates the Disconnect Code for Kit.
1 = 40 Amp; 2 = 80 Amp; 3 = 100 Amp
HEATER
MOTOR
CONT. CKT.
SERIAL NO
480V
120V
1
1
.28
10
V.A.
MAX.
P/N 196-057744-002
Figure 14 — Nameplate
Figure 13 — Pressure Sensitive Label
REPLACEMENT PARTS LIST
Disconnect
Size
Kit Model #
Disconnect
Cover Plate
Mounting Bracket
50 Amp
80 Amp
100 Amp
KDS-1
KDS-2
KDS-3
292-303472-001
292-303472-002
292-303472-008
220-303485-010
220-303485-003
220-303485-003
220-303484-003
220-303484-003
Limited Warranty:
Please refer to the Chromalox limited warranty applicable to this product at
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