Watlow E-SAFE II Hybrid Power Switch User Manual

How to Reach Us

To be automatically connected to the nearest North American
Technical and Sales Office call:

1-800-WATLOW2

International T echnical and Sales Offices:

Australia [phone]
China [phone]
France [phone]
Germany [phone]
Italy [phone]
Japan [phone]
Korea [phone]
Malaysia [phone]
Mexico [phone]
Singapore [phone]
Spain [phone]
Sweden [phone]
Taiwan [phone]
United Kingdom [phone]

Your Authorized Watlow Distributor:

E-SAFE® II Hybrid Power Switch

User’s Manual

For other product information:

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

About Watlow

Watlow Electric Mfg. Co., has been manufacturing industrial electric
heating products since 1922 and is located in St. Louis, Missouri. Watlow
products include electric heaters, sensors, controllers and switching
devices. Watlow's facility in Winona, Minnesota 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 to provide compatibly
engineered controls that they can incorporate into their products with
confidence. The controls operation resides in a 100,000-square-foot

marketing, engineering and manufacturing facility in Winona, Minnesota.

Warranty

The Watlow ESAFE® II Hybrid Power Switch is warranted to be free of
defects in material and workmanship for 24 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 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.

Quality and Mission Statement:

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

1241 Bundy Boulevard, Winona, Minnesota USA 55987-5580

Phone: [phone] Fax: [phone]

Internet: http://www.watlow.com

English

0600-0055-0001 Rev C

June 2008 Multiple U.S. and international patents pending.

Safety Information

We use note, caution and warning symbols throughout this

ç

CAUTION or
WARNING

Ó

Electrical
Shock Hazard
CAUTION or
WARNING

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].

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, 1241
Bundy Blvd., P.O. Box 5580, Winona, Minnesota, USA 55987­5580; telephone: [phone]; fax: [phone]. ©
Copyright 2007 by Watlow, Inc. All rights reserved.

240VÅ

L3

L2

L1

1

Fuse

Reset

Breaker

Series SD

SD3_-_K_ _-_ _RG

234

56

Fuse

Series LV

LVC6KW-4542500A

1
2

3

4

5

Neutral

L3

480VÅ

L2

Fuse

8

9

1011

6
7

8

9

10

240VÅ

120VÅ

Fuse

Fuse

Input

120V

Fuse

CR1
Coil

7

A1

Å

CR1

L1

1

A2

T1

2

Thermocouple

Thermocouple

L2

3

T2

4

Control

High Limit

L3

5

T3

6

Connected

®

II

E-SAFE
Hybrid Power
Switch
ES2X-2XX0-0000

Delta

T3

Heater

T2 T1

4-Wire Wye

Connected Heater

T3

Wye

T2 T1

Connected

Heater

N

L1

1

Fuse

Reset

Breaker

Series SD

SD3_-_K_ _-_ _RG

234

56

Fuse

Series LV

LVC6KW-4542500A

1
2

3

4

5

Fuse

Fuse

480VÅ

120VÅ

8

9

1011

6
7

Fuse

8

9

10

Fuse

Input

120V

CR1
Coil

7

A1

Å

CR1

L1

1

A2

T1

2

Thermocouple

L2

3

T2

4

Control

L3

5

T3

6

Connected Heater

E-SAFE
Hybrid Power
Switch
ES2X-3XX0-0000

4-Wire Wye

High Limit
Thermocouple

®

II

System Wiring Example 240 volt, 3-phase, 3 pole
with ac input control

Note:

ES2X-2XX0-0000 is powered via L1, L2

N

L1

120VÅ

1

Fuse

Reset

Breaker

Series SD

SD3_-_K_ _-_ _RG

234

56

Fuse

Series LV

LVC6KW-4542500A

1
2

3

4

5

CR1

L1

1

7

A1

A2

Input

8

9

1011

120V

T1

2

Å

Thermocouple

Fuse

Fuse

CR1

Coil

Thermocouple

6
7

8

9

10

L3

L2

5

3

T2

T3

4

6

®

E-SAFE

II
Hybrid Power
Switch
ES21-1HV0-0000

Control

High Limit

System Wiring Example 120 volt, single-phase, 1
pole with ac input control

System Wiring Example 277/480 volt, 3-phase, 3
pole with ac input control, 4-wire Wye connected
heater only

Note:

ES2X-3XX0-0000 is powered via terminal (7) and L1

L2

Å

240V

L1

1

Fuse

Reset

Breaker

Series SD

SD3_-_K_ _-_ _RG

234

Fuse

Series LV

LVC6KW-4542500A

1
2

3

4

5

56

Fuse

240V

89

1011

6
7

8

9

10

120V

Fuse

Fuse

Fuse

Å

CR1

L3

L2

L1

1

7

Å

A1

A2

Input

T1

120V

2

Å

Thermocouple

CR1

Coil

Thermocouple

3

T2

T3

4

6

E-SAFE
Hybrid Power
Switch
ES22-2HV0-0000

Control

High Limit

5

®

II

System Wiring Example 240 volt, single-phase, 2
pole with ac input control

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 loss of life. See the product rating curve for wire gauge selection, ambient temperature and current restrictions.

∫

WARNING:
Only authorized and qualified personnel should install and service the E-SAFE II Hybrid Power Switch. Failure to comply with these recom­mendations may result in damage to equipment and property and injury to personnel.

Torque Guidelines:

Properly torque line and load terminals to 2.25 nm (20 in-lbs).

NOTE:

Do not use an RC snubber on the temperature control command signal output. The leakage current through
a snubber circuit can turn the E-SAFE II relay on, even when the command signal is off.

Snubbers Snubbers Snubbers