E-SAFE® II Hybrid Power Switch User Manual Rev C June
Contents
1. A Monitor the temperature of terminals using thermocouples between the ring terminal and connectors L1 L2 or L3 The temperature must not exceed 95 C B Monitor the temperatures of wire insulation using a thermocouple located 3 inches from the connector The temperature must not exceed the insulation rating of the wire A A WARNING Thermocouples attached to terminals will be at load voltage potential measurements need to be taken with isolated equipment or isolate the sensor from the terminal with suitable insulation WARNING Do not use an ungrounded wye or delta wired heater configuration at 400 or 480V ac Failure to follow all specifications and wiring instructions may result in property damage personal injury and or loss of life CAUTION Provide proper enclosure ventilation to maintain an oper ating environment less than 70 C 158 F maximum ambient rating Failure to do so could cause damage to equipment and property Torque Guidelines Properly torque line and load terminals to 2 25 nm 20 in lbs Side a A i H HH EEE 46 99 mm 1 85 in rH in A 23 88 mm 0 94 in Y y 0 10 32 7x ANK 1 4 x 0 032 holes and slots for fit male Q D 2x with 10 screws Specifications Output voltage e 100 120V ac 10 15 percent 50 60Hz e 200 240V ac 10 15 percent 50 60Hz e 230 277V ac 10 15 percent 50 60Hz Output amperage e Up to 35 amperes single dual and three ph2. How to Reach Us E SAFE II Hybrid Power Switch To be automatically connected to the nearest North American Technical and Sales Office call 1 800 WATLOW2 User s Manual International Technical and Sales Offices Australia 61 3 9335 6449 China 86 21 3950 9510 France 33 01 3073 2425 Germany 49 0 7253 9400 0 Italy 39 02 458 8841 Japan 81 3 3518 6630 Korea 82 2 575 9804 Malaysia 60 3 7980 7741 Mexico 52 442 217 6235 Singapore 65 6777 1266 Spain 34916751 292 Sweden 46 35 27 11 66 Taiwan 886 7 288 5168 United Kingdom 44 0 115 964 0777 Your Authorized Watlow Distributor Der LOW 1241 Bundy Boulevard Winona Minnesota USA 55987 5580 Phone 1 507 454 5300 Fax 1 507 452 4507 Internet http Awww watlow com English For other product information 0600 0055 0001 Rev C Watlow FAX REPLY 1 732 885 6344 outside the U S or 1 800 367 0430 inside the U S June 2008 Multiple U S and international patents pending About Watlow Safety Information Watlow Electric Mfg Co has been manufacturing industrial electric We use note caution and warning symbols throughout this heating products since 1922 and is located in St Louis Missouri Watlow A N book to draw your attention to important operational and products include electric heaters sensors controllers and switching safety information devices Watlow s facility in Winona Minnesota has been designing CAUTION or so
3. ase e 30A 277V ac Operating environment e Oto 70 C 32 to 158 F operating temperature e 0 to 90 percent RH non condensing e Operational life Four million switching cycles e Installation category III Pollution degree 2 Control mode e No arc hybrid contactor Input command signal e 3 to 32V dc 24V ac 20 20 percent e 100 to 240V ac 10 15 percent 85 to 264V ac Input command signal terminals e 1 4 inch fast on appliance Line and load terminals e No 10 screw will accept ring terminals locking fork terminals or block fork terminals 1 4 in 6 35 mm by 10 32 e Wire insulation temperature can be determined through testing described in the U L Conditions of Acceptability Ordering Information Number of Poles 1 1 pole 2 2 poles controlled 3 3 poles controlled Load Voltage 1 100 to 120V ac 2 200 to 240V ac 3 230 277V ac 400 480V ac with wye star neutral connected to center required Command Signal Voltage LV Low voltage 3 to 24V dc or 24V ac HV High voltage 100 to 240V ac 10 15 percent 85 to 264V ac Future Option Future Option Custom Parameters 000 Standard product Mounting e Back panel mount e Horizontal or vertical mounting options with equal product performance 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 w
4. hen the command signal is off Coxe Declaration of Conformity Series Esafe II Relay Watlow Winona Inc 1241 Bundy Blvd Winona MN 55987 USA Declares that the following product Designation Model Numbers Classification Series Esafe Il Relay ES2 1 2 or 3 1 2 or 3 LV or HV O O any three letters or numbers AC51 Semiconductor Direct on line contactor CE Installation Category III Pollution degree 2 IPOO Rated Voltage and Frequency 100 120 Vac 200 240 Vac 230 277 Vac Star or Wye with Center connected Neutral required Rated Power Consumption 35A Resistive Load Maximum Meets the essential requirements of the following European Union Directives by using the relevant standards show below to indicate compliance 2004 108 EC Electromagnetic Compatibility Directive Low Voltage switchgear and controlgear Part 4 3 Contactors and motor starters AC semiconductor controllers and contactors for non motor loads Class B Emissions Electrical Fast Transient Burst Immunity Voltage Dips Short Interruptions and Voltage Variations Immunity Harmonic Current Emissions gt 16A lt 75A EN 60947 4 1 2004 CRGD EN 60947 4 3 2000 2005 EN 61000 4 2 1996 A2 2001 Electrostatic Discharge Immunity EN 61000 4 3 2002 Radiated Field Immunity EN 61000 4 4 2004 EN 61000 4 5 1995 A2 2001 Surge Immunity EN 61000 4 6 1996 A3 2005 Conducted Immunity EN 61000 4 8 1994 A1 2001 Magnetic Field I
5. le with ac input control 4 wire Wye connected Note heater only ES2X 2XX0 0000 is powered via L1 L2 Note ES2X 3XX0 0000 is powered via terminal 7 and L1 oo 240V L2 O L1 O N 120V L1 om Breaker Breaker CR1 Series SD Input 142 122 4 elelejelele ESAFE I HEN ES EERE Hybrid Power Switch ES21 1HV0 0000 Na E SAFE II Hybrid Power Switch ES22 2HV0 0000 1 A Control Thermocouple Control Thermocouple High Limit DE Thermocouple P System Wiring Example 120 volt single phase 1 System Wiring Example 240 volt single phase 2 pole with ac input control pole with ac input control 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 A WARNING Only authorized and qualified personnel should install and service the E SAFE II Hybrid Power Switch Failure to comply with these recom mendations may result in damage to equipment and property and injury to personnel Torque Guidelines Properly torque line and load ter
6. lid state electronic control devices since 1962 and has earned the A NOTE marks a short message to alert you to an important reputation as an excellent supplier to original equipment manufacturers WARNING detail These OEMs and end users depend upon Watlow to provide compatibly A CAUTION safety alert appears with information that is engineered controls that they can incorporate into their products with important for protecting your equipment and performance Be confidence The controls operation resides in a 100 000 square foot especially careful to read and follow all cautions that apply to marketing engineering and manufacturing facility in Winona Minnesota your application AN A WARNING safety alert appears with information that is important for protecting you others and equipment from Wa rra nty Electrical damage Pay very close attention to all warnings that apply to The Watlow ESAFE II Hybrid Power Switch is warranted to be free of Shock Hazard your application defects in material and workmanship for 24 months after delivery to the The safety alert symbol an exclamation point in a trian first purchaser for use providing that the units have not been misapplied CAUTION or gle precedes a general CAUTION or WARNING statement Since Watlow has no control over their use and sometimes misuse we f f f f cannot guarantee against failure Watlow s obligations hereunder at WARNING The electrical hazard sy mbol A a lightning bo
7. lt in a Watlow s option are limited to replacement repair or refund of purchase triangle precedes an electric shock hazard CAUTION or price and parts which upon examination prove to be defective within WARNING safety statement the warranty period specified This warranty does not apply to damage resulting from transportation alteration misuse or abuse Technical Assistance If you encounter a problem with your Watlow controller Retu rns review your configuration information to verify that your selections are consistent with your application inputs out e Call or fax your distributor or the nearest Watlow sales office for best puts alarms limits etc If the problem persists after checking information about returns See outside back cover the configuration of the controller you can get technical assis tance from your local Watlow representative see back cover e To return directly to Watlow in the U S first call or fax Customer or in the US dial 1 507 494 5656 Service for a Return Material Authorization RMA number telephone 1 507 454 5300 fax 1 507 452 4507 Please have the following information available when calling e Put the RMA number on the shipping label along with on a written e Complete model number e User s Manual description of the problem e A restocking charge of 20 of the net price is charged for all standard Yo ur Co mm ents units returned to stock We welcome your comments or suggestions on thi
8. minals 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 E Safe ll Product Rating 5 5 10 15 20 25 30 3 70 C 6AWG 90 C _ li 65 C 60 C AMBIENT TEMPERATURE 35 C AMPERAGE These ratings apply to 3 phase units with cycle times of 30 sec onds or more Consult the factory for 1 and 2 phase unit ratings A A 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 tem perature 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 Unit Dimensions 6 35 mm 0 25in TOP 97 03 mm 3 82 in 82 55 mm 3 25 in 14 88 mm 48 51 mm 0 586 in 1 910 in 140 72 mm gt 5 54 in U L Conditions of Acceptability Applications must be tested as described below for spe cific wire insulation or specific wire gauge sizes Tests shall be performed in the end application under worst case operating conditions Test Procedure
9. mmunity EN 61000 4 1 1 2004 IEC 61000 3 12 2004 IEC 61000 3 11 2000 Voltage Fluctuations and Flicker gt 16A lt 75A NOTE 1 To comply with flicker requirements cycle time may need to be greater than 12 seconds if Load Power is 16A to comply with standard or the maximum source impedance needs to be determined Source impedance shall meet EN 61000 3 11 requirements for load currents gt 16A 2006 95 EC Low Voltage Directive EN 60947 1 EN 60947 4 3 2004 2000 CRGD 2005 Low Voltage switchgear and controlgear Part 4 3 Contactors and motor starters AC semiconductor controllers and contactors for non motor loads Compliant with 2002 95 EC ROHS Directive 2002 96 EC WEEE Directive Fi Equipment Requires Recycling Raymond D Feller Ill Name of Authorized Representative General Manager Title of Authorized Representative Winona Minnesota USA Place of Issue February 2008 Date of Issue
10. s user s manual Please send them to Technical Writer Watlow 1241 a ee Bundy Blvd P O Box 5580 Winona Minnesota USA 55987 Quality and Mission Statement 5580 telephone 1 507 454 5300 fax 1 507 452 4507 Copyright 2007 by Watlow Inc All rights reserved Watlow will be the world s best supplier of superior thermal solu tions by exceeding the expectations of our customers sharehold ers and employees Neutral LBO X Lot gt 240V L2 C 480V Lo ex o L1 o L1 Ori o a Breaker Breaker Q Fuse Fuse 480V Ri 7 ft a F 7 o e 5 E SAFE II 120V E SAFE II Hybrid Power Jii SD Hybrid Power Switch Input a2 O 12 1 ES2X 2XX0 0000 12345 Input maz O n G D EAT olojojolojo nr eT a lelelelelele ee oe oe oe ane Delta ee eens Connected N i e Heater Fuse Fuse S 4 Wire Wye D D Connected Heater l qa 4 Wire Wye ya A Connected Heater pi A A de High Limit Control Control Thermocouple Thermocouple Thermocouple a High Limit Thermocouple T2 Wye Connected Heater System Wiring Example 240 volt 3 phase 3 pole System Wiring Example 277 480 volt 3 phase 3 with ac input control po
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