3 Thermostats&Access 11/22/00 11:04 AM Page 423

W A T L O W

Tubular and

Thermostats Accessories
Process Assemblies
Thermostats and Thermostats with Enclosures
Accessories NEMA 1 Single and Double Pole NEMA 4 and 12 Single Pole
Thermostats regulate temperature in 3 3/16
(91 mm)
non-critical applications. They sense
temperature, within a preset range 3 1/4"
2 3 /4 7 /16
(83 mm)
and cycle heaters on and off to 2 /32"
5
3 5 /16"
(70 mm) (88 mm)

maintain the set point. (55 mm) (84 mm)

(2) 0.218"
Thermostats may be mounted inside 4 3/8 (112 mm) (6 mm) Dia. Holes
a terminal enclosure or remote
mounted (separate from the heater 2 15/16
assembly). If using a remote (75 mm)
mounted thermostat, be sure to
order sufficient capillary tube length
to permit installation. 5 13 /16"
NEMA 7 Single Pole 4 5/8"
(148 mm) (117 mm)
All Watlow thermostats are normally
closed circuit and either single pole, 31/4"
(2) 1/2" (83 mm)
single throw (SPST) or double pole, (56 mm)
single throw (DPST). They can be
2 3/16" 5 5/16"
used with or without an enclosure. (56 mm) (135 mm)
6 3/8"
Thermostat selection should be 3" (162 mm)
(76 mm)
based on temperature range,
capillary tube length and sensor
NEMA 4 and 12 Double Pole NEMA 7 Double Pole
bulb size (diameter/length). / 7 3/4"
6 9/16" (197 mm)
Remote Mount Thermostat (167 mm)
Assemblies
7"
Remote mounted thermostat (178 mm)
assemblies can be supplied with the 6"
6 9/16" (152 mm)
following enclosures: (167 mm)

• General purpose (NEMA 1)

1/2" (13 mm)
• Moisture resistant (NEMA 4) 6 1/2"
(165 mm)
• Explosion resistant (NEMA 7)
• Explosion/moisture resistant
(NEMA 7/4) 4 1/4" 6 1/4"
• Dust resistant (NEMA 12) (108 mm) (164 mm)

Pilot Light 6"

An optional pilot light gives visual (152 mm) 8 3/4" 7/16"

indication whether the power (220 mm) (11 mm)

supplied to the heating element(s) is

on or off.
To order, please specify suffix code
PL11.
Thermostat Conversion Kits
Kits are available to convert a
heater’s general purpose (NEMA 1)
terminal enclosure to accept either a
single or double pole thermostat.
Incoloy® is a registered trademark of
Special Metals Corporation.
The kit contains all the necessary
parts to change out the existing
terminal enclosure cover and mount
the thermostat inside. These are
hardware and wiring kits only.
Single pole conversion kit covers
1, 11⁄4 , 2 and 21⁄2 inch NPT screw
plugs. To order, specify code
K492-000-35-(thermostat type).
Double pole conversion kit covers
2 and 21⁄2 inch NPT screw plugs. To
order, specify code K492-000-34-
(thermostat type).
Celsius Dial Scale
Thermostats are shipped with
Fahrenheit (°F) dial scales. If your
application requires a Celsius (°C)
scale, order the optional dial face.
To order, specify code CD. Scale
will match thermostat temperature
range.
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Tubular and
Process Assemblies
Thermostats and
Accessories
Application Hints
• Locate the thermostat where
ambient temperatures do not
exceed 150°F (65°C).
• Mount the thermostat in an
enclosure that is compatible with
the surrounding environment.
• Immerse the entire sensing bulb
in the media being heated.
• Make sure the sensing bulb is
mounted away from the heating
element(s) to negate any undue
influence on the sensing bulb’s
temperature “reading.”
• Keep the capillary tube insulated
from electrical connections.
• Do not use a thermostat for high-
accuracy temperature sensing.
Use an appropriate
thermocouple, RTD or thermistor
and temperature control.
• Do not use thermostats as a
primary power switching device.
Use a disconnect switch or
circuit breaker to cut power when
servicing.
• Interconnect the thermostat to the
heater only if:
- The heater has one circuit
- The heater’s ampere draw is
lower than the thermostat’s rated
ampacity at prescribed voltage.
• Interconnect either a single or
double pole thermostat with a
single-phase heater when the
supply voltage does not exceed
277VÅ(ac) for SPST or 480VÅ(ac)
for DPST.
• Only interconnect three-phase
delta heaters to DPST
thermostats.
• Use a single pole thermostat for
pilot duty where the thermostat is
not interconnected with the
heater, or heater exceeds the
volt/amp rating.
Warning
Do not use thermostats for high-limit
sheath protection. Thermostats fail
in a closed circuit mode and will not
cut power to the heaters. Limit
control should be provided by an
isolated, redundant sensor and
control system of the appropriate
type, design and installation.
Thermostats are precalibrated at the
factory. No adjustment, other than
selecting the desired operating
temperature, is required. All wiring
should be performed by qualified
personnel and comply with the
National Electrical Code and other
applicable state and local codes.
To help assure you select the
correct thermostat, as well as install
and wire it properly, we have put
together a few helpful hints.
Schematics are provided for
interconnecting thermostats to
single- and three-phase heaters.

Pilot Duty Wiring

SPST,1-phase SPST, 3-phase delta SPST, 3-phase wye
1 L1 1 L1 1 L1

1 L2
1 L2
1 L3
1 L3 1 L2

SPST SPST
SPST
120VÅ(ac) 120VÅ(ac)
P P
120VÅ(ac)
P

Interconnected Wiring
SPST, 1-phase DPST, 1-phase DPST, 3-phase delta
SPST 1 L1
DPST DPST
1 L1 1 L1
P
P
P 1 L2

1 L2
1 L3
1 L2

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W A T L O W

Tubular and

Thermostats Accessories
Process Assemblies F.O.B.: Hannibal, Missouri

Thermostats and
Accessories
Thermostat
Control Temperature Ampacity @ Bulb Bulb Capillary Terminal Code Est. Net
Mode Type Range Differential Line Voltage Diameter Length Length Type No. Weight
°F (°C) ˚F (˚C) 120 240 277 480 inch (mm) inch (mm) inch (mm) lbs (kg)
On-off Single 30-110 (0-40) 8 (0) 25 25 22 — 0.250 (6) 4 3⁄4 (121) 18 (455) 1 1 (0.4)
Temp Pole 30-250 (0-120) 15 (8) 25 25 22 — 0.250 (6) 3 1⁄4 (85) 18 (455) #12 AWG 2 1 (0.4)
Control Single 30-250 (0-120) 15 (8) 25 25 22 — 0.250 (6) 3 1⁄4 (85) 84 (2135) Stranded 2A 1 (0.4)
Throw 175-550 (80-290) 26 (14) 25 25 22 — 0.250 (6) 3 3⁄8 (85) 18 (455) Leads 3 1 (0.4)
(SPST) 175-550 (80-290) 26 (14) 25 25 22 — 0.250 (6) 2 3⁄4 (70) 84 (2135) 3A 1 (0.4)
300-700 (150-350) 12 (7) 25 25 — — 0.375 (10) 3 3⁄4 (95) 60 (1525) 10 1 (0.4)
60-160 (15-70) 19 (10) 30 30 30 20 0.250 (6) 4 3⁄8 (110) 14 (355) #8-32 12A 1 (0.4)
Double 30-110 (0-40) 12 (7) 30 30 30 21 0.375 (10) 6 1⁄4 (160) 36 (915) 4 2 (0.9)
Pole 60-250 (15-120) 12 (7) 30 30 30 21 0.375 (10) 4 1⁄2 (115) 48 (1220) #10-32 5 2 (0.9)
Single 60-250 (15-120) 12 (7) 30 30 30 21 0.250 (6) 6 1⁄2 (165) 48 (1220) Screw Lug 5A 2 (0.9)
Throw 100-550 (40-290) 22 (12) 30 30 30 21 0.375 (10) 3 7⁄8 (100) 48 (1220) 7 2 (0.9)
(DPST) 100-550 (40-290) 22 (12) 30 30 30 21 0.250 (6) 7 1⁄16 (179) 48 (1220) 7A 2 (0.9)
On-off (DPST) 60-250 (15-120) 12 (7) 30 30 30 — 0.250 (6) 6 1⁄2 (165) 48 (1220) #10-32 8 2 (0.9)
with 100-550 (40-290) 22 (12) 30 30 30 — 0.188 (8) 12 (305) 48 (1220) Screw Lug 9 2 (0.9)
Manual (SPST) 350➀ (180) — 30 30 20 — 0.250 (6) 3 1⁄2 (90) 36 (915) #10-32 11 1 (0.4)
Reset Screw Lug

➀ Fixed temperature setting

Availability
Stock: Same day shipment

Cross-Reference For Order With

How to Order - - Replacement Thermostat This Number

202-0-21-1 (small knob) 1
202-0-21-2 (small knob) 202-0-21-2MB
Thermostat Code Number 202-0-21-4 2
(See stock chart above) 202-0-21-5 2A
202-0-21-3 3
Enclosure (Remote Mount Only)
202-0-21-8 (small knob) 202-0-21-8M
S = General purpose (NEMA 1)
202-0-21-6 3A
W = Moisture resistant (NEMA 4)
202-0-4-2 4
E = Explosion resistant (NEMA 7) 202-0-4-6 5
E/W = Explosion/moisture resistant (NEMA 7/4) 202-0-4-17 5A
D = Dust resistant (NEMA 12) 202-0-4-5 7
Options 202-0-4-16 7A
CD = Celsius dial scale 202-0-3-1 8
202-0-3-3 9
CB = Chrome bezel
202-0-1-13 10
LTB = Liquid-tight brass fitting (3⁄8"-18 NPT)
202-0-29-2 11
PL11 = Pilot Light 202-0-41-2 (small knob) 12A

If you only have the thermostat code number

use this cross-reference chart.
Availability
Thermostats Modified Stock➁: Three to five ➁ Stock or Assembly Stock units with catalog
Stock: Same day shipment working days options.

Remote Mount Thermostats Standard: Eight to 10 working days

Stock: Same day shipment Options, complexity and quantity
Assembly Stock: Three to five may affect availability and lead
working days times. Consult factory.

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Tubular and
Process Assemblies F.O.B.: Hannibal, Missouri

Thermostats and General Purpose (NEMA 1) Enclosure

3/4" NPT Conduit Opening
Accessories ® 1/2"
FIREROD
®

Cartridge Heater (13 mm)

Low Liquid Level Sensor Dia.

The Watlow low liquid level sensor • Application should tolerate

can protect a heating system by
sensing when a liquid drops below a
predetermined level. This is
accomplished by locating the
sensor at the minimum desired
liquid level in the tank or vessel. The
sensor’s ASTM Type J thermocouple
output can be connected to a
variety of controls, alarms and limit
protection devices.
To provide an additional margin of
protection, the Type J thermocouple
makes this low liquid level sensor
respond considerably faster than
conventional capillary bulb
thermostats.
To order, specify code number
BCN5J1SJ.
Application Hints
• Only use sensor in non-
flammable liquids that are
compatible with the Incoloy®
sheath and 304 stainless steel
screw plug.
sheath temperature at limit set 1 2"
/ (13 mm)
No-Heat
point. 51/2" (140 mm)
• The time delay between the low
liquid level condition on-set, and Specifications
the sensor’s ability to signal the Screw plug: 1" NPT
control device should be
Plug material: 304 stainless steel
adequate to protect the heater(s).
See Installation and Maintenance Sheath material: Incoloy®
Instructions for details. Watt density: 13 W/in2 (2 W/cm2)
Controller Recommendation Watts: 100
• Use Watlow Safety Limit Volts: 120VÅ(ac)
Temperature Control Series 142 Immersed length: 51⁄2 inch (140 mm)
(Code number 142A-3605-1300).
Thermocouple: ASTM Type J
This controller features compact
sub-panel mounting and is sealed Est. ship. wt.: 2 lbs (1 kg)
against ambient environment.
UL® recognized for limit Availability
protection (UL 991, “Tests For Stock: Same day shipment
Safety-Related Controls Modified Stock➀: Five to seven
Employing Solid State Devices”). working days
Made-to-Order: Four to six weeks
Controller supplied by Watlow’s Options, complexity and quantity
Winona, Minnesota facility. may affect availability and lead
times. Consult factory.
➀ Stock units with catalog options.

Protective Wells Internal 3/8" - NPT 0.500" O.D.

Protective wells isolate and protect
thermostat bulbs and other
temperature sensors (thermo- Immersed Length
1/2" NPT B ± 1/4" (6 mm)
couples, RTDs or thermistors). They
allow inserting the sensing element Protective Wells
sufficiently into the media being Plug and Immersed Est. Ship.
heated without being damaged. Thermowell B Dimension Code No. Weight
Steel or stainless steel protective Material inch (mm) lb (kg)
wells are available in three lengths. 12 (305) PWS12 1 (0.5)
They are supplied with 1⁄2 inch NPT Steel 24 (610) PWS24 2 (1.0)
36 (915) PWS36 2 (1.0)
mounting and 3⁄8 inch-18 NPT internal
thread for mating to a liquid-tight Stainless 12 (305) PWSS12 1 (0.5)
Steel 24 (610) PWSS24 2 (1.0)
bushing (LTB).
36 (915) PWSS36 2 (1.0)
All units are stock. To order, specify
Availability
the appropriate code number from
the stock table. Stock: Same day shipment Options, complexity and quantity
Modified Stock ➁: Five to seven may affect availability and lead-
working days times. Consult factory.
Made-to-Order: Three weeks ➁ Stock units with catalog options.

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