Watlow E-Safe Hybrid Relay User Manual Rev B

E-SAFE Relay

User’s Manual

Safety Information

We use note, caution and warning symbols throughout this
book to draw your attention to important operational and
safety information.

A “NOTE” marks a short message to alert you to an important
detail.

A “CAUTION” safety alert appears with information that is
important for protecting your equipment and performance. Be
especially careful to read and follow all cautions that apply to
your application.

A “WARNING” safety alert appears with information that is
important for protecting you, others and equipment from dam­age. Pay very close attention to all warnings that apply to
your application.

The safety alert symbol, ç (an exclamation point in a trian­gle) precedes a general CAUTION or WARNING statement.

The electrical hazard symbol, Ó (a lightning bolt in a trian­gle) precedes an electric shock hazard CAUTION or WARN­ING safety statement.

Technical Assistance

If you encounter a problem with your Watlow controller,
review your configuration information to verify that your
selections are consistent with your application: inputs; out­puts; alarms; limits; etc. If the problem persists after checking
the configuration of the controller, you can get technical assis­tance from your local Watlow representative (see back cover),
or in the U.S., dial [phone]. For technical support,
ask for for an Applications Engineer.

Please have the following information available when calling:

• Complete model number • User’s Manual

Your Comments

We welcome your comments or suggestions on this user’s
manual. Please send them to: Technical Writer, Watlow
Winona, 1241 Bundy Blvd., P.O. Box 5580, Winona,
Minnesota, USA 55987-5580; telephone: [phone];
fax: [phone]. © Copyright 2001 by Watlow Winona,
Inc. (2143) All rights reserved.

1241 Bundy Boulevard, Winona, Minnesota USA 55987-5580

Phone: [phone] Fax: [phone]

Internet: http://www.watlow.com

Hybrid Relay

English

Rev C
February, 2004

ç

CAUTION or

WARNING

Ó

Electrical

Shock Hazard

CAUTION or

WARNING

About Watlow Winona

Watlow Winona is a U.S. division of Watlow Electric Mfg. Co., St.
Louis, Missouri, a manufacturer of industrial electric heating products
since 1922. Watlow products include electric heaters, sensors,
controllers and switching devices. The Winona operation has been
designing solid-state electronic control devices since 1962, and has
earned the reputation as an excellent supplier to original equipment
manufacturers. These OEMs and end users depend upon Watlow
Winona to provide compatibly engineered controls that they can
incorporate into their products with confidence. Watlow Winona
resides in a 100,000-square-foot marketing, engineering and
manufacturing facility in Winona, Minnesota.

Warranty

The Watlow E-Safe Relay is warranted to be free of defects in material
and workmanship for 18 months after delivery to the first purchaser
for use, providing that the units have not been misapplied. Since
Watlow has no control over their use, and sometimes misuse, we
cannot guarantee against failure. Watlow's obligations hereunder, at
Watlow's option, are limited to replacement, repair or refund of
purchase price, and parts which upon examination prove to be
defective within the warranty period specified. This warranty does not
apply to damage resulting from transportation, alteration, misuse, or
abuse.

Returns

• Call or fax your distributor or the nearest Watlow sales office for
best information about returns. (See outside back cover.)

• To return directly to Watlow Winona in the U.S., first call or fax
Customer Service for a Return Material Authorization (RMA)
number (telephone: [phone]; fax: [phone]).

• Put the RMA number on the shipping label, along with on a written
description of the problem.

• A restocking charge of 20% of the net price is charged for all
standard units returned to stock.

United States ( headquarters)

Watlow Electric Manufacturing Co.
12001 Lackland Road
St. Louis, Missouri, USA 63146
Telephone: [phone]
Fax: [phone]

Europe:

Watlow GmbH
Lauchwasenstr. 1, Postfach 1165,
Kronau 76709 Germany
Telephone: [phone]
Fax: [phone]

Watlow France S.A.R.L.
Immeuble Somag,16 Rue Ampère,
Cergy Pontoise Cedex 95307
France
Telephone: [phone]
Fax: [phone]

Watlow Italy S.r.l.
Via Meucci 14,
20094 Corsico, Milano, Italy
Telephone: [phone]
Fax: [phone]

Watlow Limited
Robey Close, Linby Industrial Estate,
Linby, Nottingham NG15 8AA
England
Telephone: [phone]
Fax: [phone]

Latin America:

Watlow Mexico
Avenue Fundición #5,
Col. Parques Industriales,
Querétaro, Qro. México CP-76130
Telephone: [phone]
Fax: [phone]

Asia/Pacific:

Watlow Australia Pty., Ltd.
3 Belmont Place, Gladstone Park,
Tullamarine, Victoria 3043 Australia
Telephone: [phone]
Fax: [phone]

Watlow China Shanghai
Representative Office
179, Zhong Shan
Hong Qiao Cointek Bldg, Fl. 4, Unit P
Shanghai 200051 China
Telephone: [phone]
Fax: [phone]

Watlow Japan Ltd. K.K.
Azabu Embassy Heights 106,
1-11-12 Akasaka,
Minato-ku, Tokyo 107-0052 Japan
Telephone: [phone]
Fax: [phone]

Watlow Korea
3rd Fl. Han-il Bldg.
210-5 YangJae-dong, SeoCho-ku
Seoul, 137-893 Korea
Telephone: [phone]
Fax: [phone]

Watlow Malaysia Sdn Bhd
38-B Jalan Tun Dr. Awang
Bayan Lepas
Penang, Malaysia 11900
Telephone: [phone]
Fax: [phone]

Watlow Asia Engineering Pte. Ltd.
16, Ayer Rajah Crescent, #06-05A,
Ayer Rajah Industrial Estate,
Singapore 139965
Telephone: [phone]
Fax: [phone]

Watlow Electric Taiwan Corp.
10F-1 No. 189,
Chi-Shen 2nd Road,
Kaohsiung, Taiwan
Telephone: [phone]
Fax: [phone]

How to Reach Us

For other product information:

Watlow FAX REPLY: [phone], outside the U.S.; or +1 (800)
367-0430, inside the U.S.

6 0 9 4 7

S i d e

F r o n t

Top & Bottom

Unit Dimensions

ç

CAUTION: Provide proper enclosure ventilation to maintain
an operating environment <55°C maximum ambient rating.
Failure to do so could cause damage to equipment and
property.

E-SAFE Relay in Operation

Off

On

Off

Conduction Path

ç

∫

WARNING:
Wiring must conform
to National Electric
Code (NEC) safety
standards, as well as
locally applicable
codes. Failure to do
so could result in per­sonal injury or death.

∫

W A R N I N G :
Only authorized and
qualified personnel
should install and
service the E-SAFE
relay. Failure to
comply with these
r e c o m m e n d a t i o n s
may result in damage
to equipment and
property and injury to
p e r s o n n e l .

System Wiring Example

Input and Output Wiring

Torque Guidelines :

• Properly torgued line & load terminals to 3.95 nm (35 in-lbs)

• Retorque after 48 hours to minimize wire cold flow.

• Re-torque line & load terminals every 36 months.

Declaration of Conformity

Series E-Safe Relay

Watlow Winona, Inc.
1241 Bundy Blvd.
Winona, MN 55987 USA

Declares that the following product:

Designation: Series E-Safe
Model Numbers: ES (20 or 40) - 3 (024, 120, 220) - ACCE
Classification: Mechanical Relay, AC-51 Utilization

Category for Resistive Loads. Installation
Category II, Pollution degree 2

Rated Voltage and Frequency: Load 24-240 V~(ac) 50/60 Hz,

Control Signal 24 V~, 120 V~ or 200-240V~

Rated Power Consumption: Load 20 A or 40 A depending on model.

Control Signal 15 VA Max.

Meets the essential requirements of the following European Union Directives by using the relevant
standards show below to indicate compliance.

89/336/EEC Electromagnetic Compatibility Directive

EN 60947-4-3 2000 Low-voltage switchgear and controlgear - Contactors and

motor-starters - AC semiconductor controllers and contactors
for non-motor loads. Industrial Immunity, Class B emissions.

EN 61000-4-2 1995 Electrostatic Discharge Immunity
EN 61000-4-3 1996 Radiated Field Immunity
EN 61000-4-4 1995 Electrical Fast-Transient / Burst Immunity
EN 61000-4-5 1 9 9 5 , A 1 : 1 9 9 6 Surge Immunity
EN 61000-4-6 1996 Conducted Immunity
EN 61000-4-11 1994 Voltage Dips, Short Interruptions and Voltage Variations Immunity
EN 61000-3-2 2000 ED.2. Harmonic Current Emissions

73/23/EEC Low-Voltage Directive

EN 60947-4-3 2000 Low-voltage switchgear and controlgear- Contactors and

motor-starters - AC semiconductor controllers and contactors
for non-motor loads.

Raymond D. Feller III Winona, Minnesota, USA
Name of Authorized Representative Place of Issue

General Manager February 2004
Title of Authorized Representative Date of Issue

Signature of Authorized Representative

Ordering Information

(2145)

Part Number E S _ _ - _ _ _ _ - _ _ _ _

Amperage

20 = 20 amp
40 = 40 amp

Number of Poles

3 = 3-pole

Control Voltage

024 AC = 24 V~
120 AC = 120 V~
220 AC = 220 V~

Label Options

00 = Standard Product
CE = With CE mark

Specifications

(2146)

Control Mode

• Zero cross switching output

• Form A outputs, without arcing

• Cycle rate: 30 cycles per minute, maximum

Input Command Signal

• 24V~ (+10% / -10%) @ 0.375 Amperes

• 120V~ (+10% / -10%) @ 0.075 Amperes

• 220V~ (+15% / -20%) @ 0.041 Amperes

• 50/60 Hz

• Input Surge current and pulse characteristics
24 volt input = 24 Amp surge, less than 10VA required (0.41 A)
120 volt input = 16 Amp surge, less than 12VA required (0.101 A)
220 volt input = 8 Amp surge, less than 14VA required (0.063 A)

• Power factor approximate 0.58, 100 uSec pulse width or surge.

Note:
Do not use a RC snubber on the Esafe input or the temperature con­trol command signal output

Output Rating

• 20A to 40A max. per pole into a resistive load,

model number dependent

• 208/240V, 50/60 Hz, phase to phase

• 3-pole

• Leakage current: 0.5mA max.

Operating Life

• 1,000,000 switching cycles at maximum rating

Weight/Dimensions

• Weight: 0.560 Kg (1.25 lb)

• 96.0 mm (3.78 in) high x 82.3 mm (3.24 in) wide

x 90.2 mm (3.55 in) deep

Terminals

• Control input: Compression, accept 0.2 to 6 mm2(# 22 -10 AWG)

wire, torque to 0.8 Nm (7 in-lbs) maximum

• Output: Compression, accept 2.5 to 16 mm2(# 14- 6 AWG) wire,

torque to 3.95 Nm (35 in-lbs) maximum

Operating Environment

• Operating temperature, -30 to 55°C/-22 to 130°F

• 5 to 85% RH, non-condensing

• Storage temperature, -40 to 85°C/-40 to 185°F

Mounting

• Fits footprint of definite purpose relays and most 30 to 50 amp

mercury relays

Agency Approvals

• UL® 508 listed, C-UL, File #E213822

Quality and Mission Statement:

Watlow Winona will be the world’s
best supplier of superior thermal solu­tions by exceeding the expectations of
our customers, shareholders, and
employees.

Your Authorized Watlow Distributor: