Mercury Relay or MDR Retrofit Guide and User`s Manual
Contents
1. 1 Pole 250 64 Canoe 11 T a 2 18 amp J IZ 48 J 55 5 l TW P ee 2 62 _ od tia T 67 Mtg Hole 2 Pole Le 5 70 E 45 Gone e e a 27 P 7 5 wide Mg li Slot K E 27 3 78 e o E 96 9 1 LY i I yp 4 5 m pou a 27 Dia p 4 70 a L 825 Nitg Hale 119 83 ORDEI e ARAM ERU RD iD osse 3 Pole pun e e oe ot Dia D oF Mtg Slot O A 2 79 EG tp 74 98 SL SL S Gy us i 7 N of Dia ais E 5 00 Mtg Hole 5 70 127 145 Wiring lt gt 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 dea2. gA NRG iei Fa 102 Yo MR Wide Slot al us S Hd SI a E i ole 4024 d Typ p PEE LJ Mh 21 5 545 Mounting 79 288 Hole 4 00 102 3 Pole 8 32 Binding Head Screw 10 14 A W G il th b F 400 s Wi PE 194 ass Foo 4 49 t 67 ole 40 a 433 7 09 amp 2115 4 00 Mounting 102 Hole Definite Purpose Relay Foot Print HG30 XAAX 0000 2 16 65E TE PAAA 3 2 83 S Ub Mountin Slot EA t For 8 To 10 Screw 2
3. A Pressure Dimensions Connectors HG35 XLDX 0000 4 62 117 4 14 A W G HG50 XMDX 0000 4 62 117 34 14 A W G HG60 XPDX 0000 5 12 130 1 8 A N G 1 Pole Pressure 2 00 Connector 51 5 4 o i ix 1 94 ay S 49 j 1 19 2 225 bia t 30 67 ole 2 Pole Pressure Connector e e i b i M d A 2 X 2 65 Hole lt 67 I el d i J J 21 5 S S Dia Mtg HBR WE 26 SES 4 00 605 7 102 3 Pole Connecter m VE cac wide Slot et 2s p Cu IL Hole e D 2 65 ja hi e q 67 WA JLI O 21 S S i Dia Mig T NN ii i 375 Hole o 79 95 Screw e 4 00 N WARNING Mercury displacement relay must be mounted vertically Failure to do this will prevent the contacts from turning off which will supply full voltage to the load Failure to follow this guideline could result in damage to equipment and personal injury or death N WARNING Mercury displacement relay contacts will switch ac current only Not for use with dc current Failure to follow this guideline could result in damage to equipment and personal injury or death Watlow Series HG Mercury Displacement Relay User s Manual All 80 100 and 150 Amp Models A Pressure Dimensions Connectors HG80 XABX 0000 5 77 147 1 8 A W G HG1M XACX 0000 5 77 147 111 8 A W G HG2M XADX 0000 6 40 163 11 0 2 A W G
4. HG60 6PD2 0000 HG60 9PD2 0000 HG60 1PD3 0000 HG60 4PD3 0000 HG60 6PD3 0000 HG60 9PD3 0000 Watlow Controls Durakool Equivalent LF 701120AC LF 70124AC LF 70124DC LF 701208ACDV LF2 701120AC LF2 70124AC LF2 70124DC LF2 701208ACDV LF3 701120AC LF3 70124AC LF3 70124DC LF3 701208ACDV 1035A120AC 1035A24AC 1035A24DC 1035A208ACDV 2035A120AC 2035A24AC 2035A24DC 2035A208ACDV 3035A120AC 3035A24AC 3035A24DC 3035A208ACDV 1050A120AC 1050A24AC 1050A24DC 1050A208ACDV 2050A120AC 2050A24AC 2050A24DC 2050A208ACDV 3050A120AC 3050A24AC 3050A24DC 3050A208ACDV 1060APS120AC 1060APS24AC 1060APS24DC 1060APS208ACDV 2060APS120AC 2060APS24AC 2060APS24DC 2060APS208ACDV 3060APS120AC 3060APS24AC 3060APS24DC 3060APS208ACDV MDR to Solid State Alternatives Cross Reference Product Description 30A NEW 25A OLD 1 POLE 120VAC COIL 30A NEW 25A OLD 1 POLE 24VAC COIL 30A NEW 25A OLD 1 POLE 24VDC COIL 30A NEW 25A OLD 1 POLE 208 240VAC COIL 30A NEW 25A OLD 2 POLE 120VAC COIL 30A NEW 25A OLD 2 POLE 24VDC COIL 30A NEW 25A OLD 2 POLE 208 240VAC COIL 30A NEW 25A OLD 3 POLE 120VAC COIL 30A NEW 25A OLD 3 POLE 24VAC COIL 30A NEW 25A OLD 3 POLE 24VDC COIL 30A NEW 25A OLD 3 POLE 208 240VAC COIL 30A NEW 35A 1 POLE 120VAC COIL 35A 1 POLE 24VAC COIL 35A 1 POLE 24VDC COIL 35A 1 POLE 208 240VAC COIL 35A 2 POLE 120VAC COIL 35A
5. 8AWG 1 8AWG 1 0 2AWG Terminations bhs bhs pc pc pc pc pc pc Coil Wire 6 32bhs 6 32bhs 6 32bhs 6 32bhs 6 32bhs 6 32bhs 6 32bhs 6 32bhs Terminations up to up to up to up to up to up to up to up to 12AWG I6AWG 12AWG 12AWG 12AWG 12AWG 12AWG 12AWG Load Type Resistive Resistive Resistive Resistive Resistive Resistive Resistive Resistive Maximum Load Voltage ac 480 600 480 600 600 600 480 600 480 480 480 600 Load Frequency 50 60 Hz 50 60 Hz 50 60 Hz 50 60 Hz 50 60 Hz 50 60 Hz 50 60 Hz 50 60 Hz Pull in Time 70 mS 50 mS 70 mS 70 mS 70 mS 90 mS 90 mS 90 mS Drop out Time 90 mS 70 mS 90 mS 90 mS 90 mS 140 mS 140 mS 140 mS Operating Ambient 35 to 55 C 35 to 55 C 35 to 55 C 35 to 55 C 35 to 55 C 35 to 55 C 35 to 55 C 35 to 55 C Storage Temperature 40 to 100 C 40 to 100 C 40 to 100 C 40 to 100 C 40 to 100 C 40 to 100 C 40 to 100 C 40 to 100 C Hg Mass Contact 1 82 oz 0 84 oz 1 75 oz 1 75 oz 1 75 oz 8 93 oz 8 93 oz 9 46 oz Weight 1 Pole 1 0 Ibs 1 0 Ibs 1 0 Ibs 1 0 Ibs 1 0 Ibs 2 0 Ibs 2 0 Ibs 2 5 Ibs 2 Pole 2 0 Ibs 2 0 Ibs 2 0 Ibs 2 0 Ibs 2 0 Ibs 3 5 Ibs 4 0 Ibs 4 5 lbs 3 Pole 2 5 Ibs 2 0 Ibs 3 0 Ibs 3 0 Ibs 3 0 Ibs 4 5 Ibs 7 0 Ibs 7 0 Ibs Agency Approvals Note pc pressure connector UL File ULE177629 bhs binding head screw CSA File LR22416 Note Watlow recommends that you do not exceed 30 HG2M XADX Load Current Table cycle
6. a letter Temp Range the range over which the controller could have the set point adjustment Thermistor a sensor that changes resistance as the temperature changes Similar but not the same as an RTD Universal Input can be a thermocouple 100 ohm DIN RTD or process volts or milliamperes VAC Volts Alternating Current VAC DC Volts Alternating Current or Direct Current VDC Volts Direct Current VTB Sw DC Variable Time Base Switched Direct Current a time proportioning DC output where the cycle time is variable These notes are used to signify areas of concern in changing to a retrofit choice These notes are also printed at the end of the retrofit listing Note 1 Note 2 Note 3 Note 4 Note 5 Note 6 Note 7 Note 8 Note 9 Retrofit controller requires a substitution of a 100 Ohm RTD sensor for the thermistor Mounting and dimensions of retrofit controller are different Verify that sufficient panel space and depth is available Retrofit controller outputs are different Add external interposing mechanical or solid state relay if applicable Retrofit controller has a programmable not fixed set point Lock set point using controller s lockout parameter For DIN rail mounting or sub panel mounting purchase DIN rail adapter p n 0822 0586 P001 for 1 32 DIN or p n 0822 0586 P002 for 1 16 DIN Add a suppressor Watlow p n 0804 0147 0000 for inductive loads Retrofit does not have equivalent action as example n
7. of current switching capability 12 24 Supply voltage can be between 12 to 24 Volts 100 240 Supply voltage can be between 100 to 240 Volts 100 ohm DIN refers to 100 ohm platinum RTD that has a DIN curve 100 ohm JIS refers to 100 ohm platinum RTD that has a JIS curve 1 32 DIN Deutsche Industrial Norm standard for panel mounted controller hole size is cut to 1 78 w x 0 88 h 1 16 DIN Deutsche Industrial Norm standard for panel mounted controller hole size is cut to 1 78 w x 1 77 h 1 8V DIN Deutsche Industrial Norm standard for panel mounted controller hole size is cut to 1 78 w x 3 63 h 1 8H DIN Deutsche Industrial Norm standard for panel mounted controller hole size is cut to 3 63 w x 1 77 h 1 88 DIN Deutsche Industrial Norm standard for panel mounted controller hole size is cut to 2 68 w x 2 68 h 14 DIN Deutsche Industrial Norm standard for panel mounted controller hole size is cut to 3 63 w x 3 63 h Action determines the direction of control Heat reverse acting or Cool direct acting Auto Reset the limit will automatically reset on a power cycle but requires manual reset on limit trip Cascade a control algorithm in which the output of one control loop provides a set point for another loop The second loop in turn determines the control action Ch Channel refers to an analog input There are single and dual channel controllers Control Mode the method that a controller uses to switch the
8. outputs such as PID ON OFF and Manual Differential control algorithm in which the output is based on the difference of the inputs plus set point DIN Deutsche Industrial Norm a set of technical scientific and dimensional standards developed in Germany RTD sensors with the DIN curve change resistance at a rate of 0 00385 ohms ohms C DIN Rail standard DIN EN50022 mounting method for attaching devices onto a metal rail Fixed refers to a set point that is fixed at one value High Limit device will deactivate output on a temperature rise above set point Inductive Load any device that has a wire winding such as solenoids electromechanical relays or transformers Input refers to the sensor types that may be connected Integral the set point in integral on board to the controller JIS Joint Industrial Standards a set of technical scientific and dimensional standards developed in Japan RTD sensors with the JIS curve change resistance at a rate of 0 00396 ohms ohms C Line Voltage the voltage required powering the electronics of the controller Low Limit device will deactivate output on a temperature drop below set point On Off a method of control that turns the output full on until set point is reached and then off until the process error exceeds the hysteresis Open Brd the form factor of this controller is an open circuit board mounted on four standoffs Manual Reset the limit must be
9. reset on a power cycle and requires manual reset on limit trip Multi RSP multiple remote set potentiometers were supported Each allowed the set point to be selected and adjusted Relay refers to an electromechanical relay Remote set point is adjusted using a remote potentiometer Panel the form factor of this controller is mounted through a hole cut in the panel PI Proportional and Integral a control mode with two functions proportional action dampens the systems response and integral corrects for droop PID Proportional Integral and Derivative a control mode with three functions proportional action dampens the systems response integral corrects for droop and derivative prevents overshoot and undershoot Potted the circuit board and electronics are encased in epoxy Proc Process input may accept 0 5 1 5 0 10 volts or 0 20 and 4 20 mA Profiling Controller will perform a sequence of programmed steps Programmable The feature is changeable in the field through jumpers and or parameter selection RTD Resistance Temperature Detector a sensor that is 100 ohms at 0 degrees C and made of platinum material SSR Solid State Relay these devices will switch AC voltage only and require a load to latch on Sw DC Switched DC a time proportioning DC output used to drive DC input solid state relays t c Thermocouple sensor device made by joining two dissimilar metals whose standards is identified by
10. snubber will reduce the flyback voltage produced by the MDR coil when it de energizes See below IAW eparately Note Watlow temperature control solid state outputs will not drive VDC coils directly Refer to the coil current specifications above and any temperature control output specifications as required by the application Watlow Series HG Mercury Displacement Relay User s Manual 4 Ordering Information WMDR XMNN 1099 HG 00 UT TUT CI Amperage 30 30 Amp 35 35 Amp 50 50 Amp 60 60 Amp 80 80 Amp 1M 100 Amp 2M 150 Amp Coil Voltage 1 120V ac 4 24V ac 6 24V dc 9 208 240V ac Option KD 30 Amp Standard LD 35 Amp MD 50 Amp PD 60 Amp AA 30 Amp Definite Purpose Relay Footprint AB 80 Amp AC 100 Amp AD 150 Amp Poles 1 1 Pole Not For Option AA 2 2Pole 3 3Pole Type 00 Standard Includes Definite Purpose Relay Footprint XX Custom 1 Call Customer Service 507 454 5300 or fax 507 452 4507 for a Return Material Authorization RMA number before returning any item for repair 2 Make sure the RMA number is on the outside of the carton and on all paperwork returned Ship on a freight prepaid basis 3 A restocking charge of 20 of the net price applies for all returned stock controls and accessories in like new condition and within 120 days after shipment Non stock and modified stock items are not returnable 4 Ift
11. 00 DC31 60K3 0000 DC11 60K2 0000 DC11 60K1 0000 DC11 60C0 0000 DC11 60K3 0000 DC21 60K2 0000 DC21 60K1 0000 DC21 60C0 0000 DC21 60K3 0000 DC31 60K2 0000 DC31 60K1 0000 DC31 60C0 0000 DC31 60K3 0000 Potential Solid State Alternatives CZ34 A60V AC1 SSR 480 50A AC1 CZ34 A60V AC2 CZ34 A48V DC1 SSR 480 50A DC1 SSR 480 50A AC1 CZ34 A60V AC1 2PCS SSR 480 50A AC1 2 PCS CZ34 A60V AC2 2 PCS CZ34 A48V DC1 2PCS SSR 480 50A DC1 2 PCS SSR 480 50A AC1 2pcs CZ34 A60V AC1 3PCS SSR 480 50A AC1 3 PCS CZ34 A60V AC2 3 PCS CZ34 A48V DC1 3 PCS SSR 480 50A DC1 3 PCS SSR 480 50A AC1 3 pcs CZ34 A60V AC1 SSR 480 50A AC1 CZ34 A60V AC2 CZ34 A48V DC1 SSR 480 50A DC1 SSR 480 50A AC1 CZ34 A60V AC1 2PCS SSR 480 50A AC1 2 PCS CZ34 A60V AC2 2 PCS CZ34 A48V DC1 2PCS SSR 480 50A DC1 2 PCS SSR 480 50A AC1 2pcs CZ34 A60V AC1 3PCS SSR 480 50A AC1 3 PCS CZ34 A60V AC2 3 PCS CZ34 A48V DC1 3 PCS SSR 480 50A DC1 3 PCS SSR 480 50A AC1 3 pcs CZ50 A48V AC1 SSR 480 50A AC1 CZ50 A48V AC2 CZ50 A48V DC1 SSR 480 50A DC1 SSR 480 50A AC1 CZ50 A48V AC1 2 PCS SSR 480 75A AC1 2 PCS CZ50 A48V AC2 2 PCS CZ50 A48V DC1 2 PCS SSR 480 75A DC1 2 PCS SSR 480 75A AC1 2 PCS CZ50 A48V AC1 3 PCS SSR 480 75A AC1 3 PCS CZ50 A48V AC2 3 PCS CZ50 A48V DC1 3 PCS SSR 480 75A DC1 3 PCS SSR 480 75A AC1 3 PCS SSR 480 75A AC1 SSR 480 75A DC1 SSR 480 75A AC1 SSR 480 75
12. 2 POLE 24VAC COIL 35A 2 POLE 24VDC COIL 35A 2 POLE 208 240VAC COIL 35A 3 POLE 120VAC COIL 35A 3 POLE 24VAC COIL 35A 3 POLE 24VDC COIL 35A 3 POLE 208 240VAC COIL 50A 1 POLE 120VAC COIL 50A 1 POLE 24VAC COIL 50A 1 POLE 24VDC COIL 50A 1 POLE 208 240VAC COIL 50A 2 POLE 120VAC COIL 50A 2 POLE 24VAC COIL 50A 2 POLE 24VDC COIL 50A 2 POLE 208 240VAC COIL 50A 3 POLE 120VAC COIL 50A 3 POLE 24VAC COIL 50A 3 POLE 24VDC COIL 50A 3 POLE 208 240VAC COIL 60A 1 POLE 120VAC COIL 60A 1 POLE 24VAC COIL 60A 1 POLE 24VDC COIL 60A 1 POLE 208 240VAC COIL 60A 2 POLE 120VAC COIL 60A 2 POLE 24VAC COIL 60A 2 POLE 24VDC COIL 60A 2 POLE 208 240VAC COIL 60A 3 POLE 120VAC COIL 60A 3 POLE 24VAC COIL 60A 3 POLE 24VDC COIL 60A 3 POLE 208 240VAC COIL 25A OLD 2 POLE 24VAC COIL 5 6 2004 DB10 60K2 0000 DB10 60K1 0000 DB10 60C0 0000 DB10 60K3 0000 DC20 60K2 0000 DC20 60K1 0000 DC20 60C0 0000 DC20 60K3 0000 DC30 60K2 0000 DC30 60K1 0000 DC20 60C0 0000 DC30 60K3 0000 DB10 60K2 0000 DB10 60K1 0000 DB10 60C0 0000 DB10 60K3 0000 DC20 60K2 0000 DC20 60K1 0000 DC20 60C0 0000 DC20 60K3 0000 DC30 60K2 0000 DC30 60K1 0000 DC20 60C0 0000 DC30 60K3 0000 DC10 60K2 0000 DC10 60K1 0000 DC10 60C0 0000 DC10 60K3 0000 DC21 60K2 0000 DC21 60K1 0000 DC21 60C0 0000 DC21 60K3 0000 DC31 60K2 0000 DC31 60K1 0000 DC31 60C0 00
13. A 6 8VA 0 133A 16 0VA 0 224A 26 9VA 208V ac 0 030A 6 2VA 0 075A 15 6VA 0 111A 23 1VA 240V ac 0 035A 8 4VA 0 087A 20 9VA 0 128A 30 7VA 24V dc 0 146A 3 5W 0 266A 6 4W 0 470A 11 3W HG80 XABX 0000 HG1M XACX 0000 HG2M XADX 0000 1 Pole 2 Pole 3 Pole Voltage Current Power Current Power Current Power 24V ac 0 930A 22 3VA 2 310A 55 4VA 5 060A 121 4VA 120V ac 0 195A 23 4VA 0 448A 53 8VA 0 968A 116 2VA 208V ac 0 097A 20 2VA 0 280A 58 2VA 0 482A 100 3VA 240V ac 0 112A 26 9VA 0 323A 77 5VA 0 563A 135 1VA 24V dc 0 219A 5 2W 0 572A 13 7W 0 555A 13 3W Temperature Control Output to MDR Coil Input Please refer to the Field Coil Power Requirements when selecting the correct temperature control output Example An HG35 1LD3 X000 requires 224mA to energize the coil and could be used with Watlow temperature control output options B or K i e 988A XXBB XXXX or 988A XXKK XXXX models The best selection is the B output option because it includes an RC snubber across the output If you select the K option it is recommended that you also purchase a Quencharc snubber separately Watlow part number 0804 0147 0000 Place the snubber across the MDR coil terminals to protect the temperature control solid state output When placing the snubber across the coil of a 2 and 3 pole relay you may have to add some lead wire to the snubber The MDR coil is an inductive load and the
14. A AC1 2 PCS SSR 480 75A DC1 2 PCS SSR 480 75A AC1 2 PCS SSR 480 75A AC1 3 PCS SSR 480 75A DC1 3 PCS SSR 480 75A AC1 3 PCS Page 1 HG Series Watlow Part Number HG30 1AA2 0000 HG30 4AA2 0000 HG30 6AA2 0000 HG30 9AA2 0000 HG30 1AA3 0000 HG30 4AA3 0000 HG30 6AA3 0000 HG30 9AA3 0000 HG80 1AB1 0000 HG80 4AB1 0000 HG80 6AB1 0000 HG80 9AB1 0000 HG80 1AB2 0000 HG80 4AB2 0000 HG80 6AB2 0000 HG80 9AB2 0000 HG80 1AB3 0000 HG80 4AB3 0000 HG80 6AB3 0000 HG80 9AB3 0000 HG1M 1AC1 0000 HG1M 4AC1 0000 HG1M 6AC1 0000 HG1M 9AC1 0000 HG1M 1AC2 0000 HG1M 4AC2 0000 HG1M 6AC2 0000 HG1M 9AC2 0000 HG1M 1AC3 0000 HG1M 4AC3 0000 HG1M 6AC3 0000 HG1M 9AC3 0000 HG2M 1AD1 0000 HG2M 4AD1 0000 HG2M 6AD1 0000 HG2M 9AD1 0000 HG2M 1AD2 0000 HG2M 4AD2 0000 HG2M 6AD2 0000 HG2M 9AD2 0000 HG2M 1AD3 0000 HG2M 4AD3 0000 HG2M 6AD3 0000 HG2M 9AD3 0000 Watlow Controls Durakool Equivalent 2030APS120AC 2030APS24AC 2030APS24DC 2030APS208ACDV 3030APS120AC 3030APS24AC 3030APS24DC 3030APS208ACDV CF 702 CF 701 CF 707 CF 713 CF2 702 CF2 701 CF2 708 CF2 713 CF3 702 CF3 701 CF3 708 CF3 713 CFC 718 CFC 717 CFC 723 CFC 734 CFC2 727 CFC2 726 CFC2 733 CFC2 734 CFC3 708 CFC3 707 CFC3 721 CFC3 734 DFC 301 DFC 307 DFC 310 DFC 311 DFC2 301 DFC2 307 DFC2 310 DFC2 311 DFC3 301 DFC3 307 DFC3 310 DFC3 311 MDR to Solid State Alternatives Cross Reference Product Description 30A 2 POLE 120VAC COI
15. L 30A 2 POLE 24VAC COIL 30A 2 POLE 24VDC COIL 30A 2 POLE 208 240VAC COIL 30A 3 POLE 120VAC COIL 30A 3 POLE 24VAC COIL 30A 3 POLE 24VDC COIL 30A 3 POLE 208 240VAC COIL 80A 1 POLE 120VAC COIL 80A 1 POLE 24VAC COIL 80A 1 POLE 24VDC COIL 80A 1 POLE 208 240VAC COIL 80A 2 POLE 120VAC COIL 80A 2 POLE 24VAC COIL 80A 2 POLE 24VDC COIL 80A 2 POLE 208 240VAC COIL 80A 3 POLE 120VAC COIL 80A 3 POLE 24VAC COIL 80A 3 POLE 24VDC COIL 80A 3 POLE 208 240VAC COIL 100A 1 POLE 120VAC COIL 100A 1 POLE 24VAC COIL 100A 1 POLE 24VDC COIL 100A 1 POLE 208 240VAC COIL 100A 2 POLE 120VAC COIL 100A 2 POLE 24VAC COIL 100A 2 POLE 24VDC COIL 100A 2 POLE 208 240VAC COIL 100A 3 POLE 120VAC COIL 100A 3 POLE 24VAC COIL 100A 3 POLE 24VDC COIL 100A 3 POLE 208 240VAC COIL 150A 1 POLE 120VAC COIL 150A 1 POLE 24VAC COIL 150A 1 POLE 24VDC COIL 150A 1 POLE 208 240VAC COIL 150A 2 POLE 120VAC COIL 150A 2 POLE 24VAC COIL 150A 2 POLE 24VDC COIL 150A 2 POLE 208 240VAC COIL 150A 3 POLE 120VAC COIL 150A 3 POLE 24VAC COIL 150A 3 POLE 24VDC COIL 150A 3 POLE 208 240VAC COIL 5 6 2004 DC20 60K2 0000 DC20 60K1 0000 Potential Solid State Alternatives ES40 3120 AC00 SSR 480 50A AC1 2PCS ES40 3024 AC00 CZ34 A48V AC2 2 PCS DC20 60C0 0000 CZ34 A60V DC1 2PCS SSR 480 50A DC1 2 PCS DC20 60K3 0000 DC30 60K2 0000 3 PCS DC30 60K1 0000 ES40 3220 AC00
16. SSR 480 50A AC1 2 PCS ES40 3120 AC00 SSR 480 50A AC1 3 PCS CZ34 A48V AC1 ES40 3024 AC00 CZ34 A48V AC2 3 PCS DC30 60C0 0000 CZ34 A60V DC1 3 PCS SSR 480 50A DC1 3 PCS DC20 60K3 0000 DD10 60K2 0000 DD10 60K1 0000 DD10 60C0 0000 DD10 60K3 0000 DD10 60K2 0000 DD10 60K1 0000 DD10 60C0 0000 DD10 60K3 0000 DD10 60K2 0000 DD10 60K1 0000 DD10 60C0 0000 DD10 60K3 0000 NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA ES40 3220 AC00 SSR 480 50A AC1 3 PCS 2PCS 2 PCS 2 PCS 2 PCS 3PCS 3 PCS 3 PCS 3 PCS Page 2 HG Series Mercury Displacement Relay User s Manual ISO 9001 m LHP e SS Registered Company Power Controls Watlow Controls 1241 Bundy Blvd P O Box 5580 Winona MN USA 55987 5580 Phone 507 454 5300 Fax 507 452 4507 WMDR XUMN 1097 June 1997 N Made in the U S A amm Supersedes WMDR XUMN Rev A00 Printed on Recycled Paper 10 Postconsumer Waste 30 Amp Models HG30 XKDX 0000 1 Pole NOTE Watlow recom mends that ring ter minal lugs be used with stranded wire on all binding head Screw terminals 318 32 Binding All 35 50 and 60 Amp Models
17. Using This Retrofit Guide This document is best viewed with Adobe Reader 6 0 To obtain the latest version of Adobe Reader visit http www adobe com Specification sheets on Watlow product may be obtained at http www watlow com literature specsheets User Manuals on Watlow product may be obtained at http www watlow com literature prodtechinfo Additional information on other Watlow products may be obtained by visiting http www watlow com To locate a controller search on the part number such as 965A 1CD0 00RG Use the Help feature in Adobe Reader on how to search documents If there are multiple listings then the retrofit is conditional upon field use Select the appropriate selection The User s Manual is included at the bottom of this document when available Before selecting a replacement controller 1 Know the application e Temperature range e Sensor type e Is the sensor upgradable if required e Additional input requirements remote set points secondary sensor or events e Output required control alarm event e Isthe power switching device upgradable e Operating voltage of controller e Mounting requirements panel space e Isa safety limit device required 2 Know the product Inputs type and number of Control function direct cool or reverse heat Outputs switched DC SSR or mechanical relay Communication requirements Which control features are required cascade slidewire di
18. fferential remote control other 3 Use your best judgment for selecting a replacement controller All applications require close examination of input output and the control mode needs to have the controller function properly 4 Safety Remember to make sure all redundant safety equipment is in place and working when retrofitting equipment If a system has been retrofitted without the proper safety equipment you could be liable if an accident occurs This is only a guide to replacement controllers If you have doubts please call 507 454 5300 and ask for technical support or email wintechsupport watlow com We re here to help The suggested replacement will differ in fit and form Please review the replacement controller specifications for suitability Carefully check the notes for additional information that may apply Your comments or suggestions on the Retrofit Guide are welcome Please send comments or corrections to Technical Writer Watlow Controls 1241 Bundy Boulevard P O Box 5580 Winona MN 55987 5580 phone 507 454 5300 fax 507 452 4507 This Retrofit Guide is copyrighted by Watlow Winona Inc February 2004 with all rights reserved 1455 Abbreviation amp Terminology as used in this document 0 5 0 5 amperes of current switching capability 2A 2 amperes of current switching capability 5A 5 amperes of current switching capability 10A 10 amperes of current switching capability 15A 15 amperes
19. he unit is unrepairable it will be returned to you with a letter of explanation Repair costs will not exceed 50 of the original cost Recycle To provide proper disposal Watlow accepts used MDRs Phone 507 454 5300 for an Return Materials Authorization RMA number Contact your Watlow representative for details The Mercury 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 abuse or improper fusing 5 Watlow Series HG Mercury Displacement Relay User s Manual Specifications WMDR XSPN 1098 Model Number HG30 XKDX HG30 XAAX HG35 XLDX HG50 XMDX HG60 XPDX HG80 XABX HG1M XACX HG2M XADX Contact Type N O N O N O N O N O N O N O N O Maximum Load See Table Current ac 30A 30A 35A 50A 60A 80A 100A Below typ Contact Resistance 4mQ 4mQ 4mQ 4mQ 4mQ 4mQ 4mQ 4mQ Load Wire 10 14AWG 10 14AWG 4 14AWG 4 14AWG 1 8AWG 1
20. o manual reset Retrofit controller does not have dual dial scale Hardware lockout is not available on retrofit Note 10 Retrofit controller does not have user selectable line voltage Note 11 Retrofit does not support remote set point or retransmit Check if pins 13 14 15 or 16 have termination If wires are on these pins select a different retrofit Note 12 Retrofit controller does not have user selectable control action Note 13 Solid state sensor required for humidity See http www vaisala com Note 14 Retrofit controller does not have user selectable control mode Note 15 Use auxiliary event board A007 1732 F4B8 Note 16 Retrofit communications are different consult specifications Note 17 Verify retrofit input range matches application HG Series Watlow Part Number HG30 1KD1 0000 HG30 4KD1 0000 HG30 6KD1 0000 HG30 9KD1 0000 HG30 1KD2 0000 HG30 4KD2 0000 HG30 6KD2 0000 HG30 9KD2 0000 HG30 1KD3 0000 HG30 4KD3 0000 HG30 6KD3 0000 HG30 9KD3 0000 HG35 1LD1 0000 HG35 4LD1 0000 HG35 6LD1 0000 HG35 9LD1 0000 HG35 1LD2 0000 HG35 4LD2 0000 HG35 6LD2 0000 HG35 9LD2 0000 HG35 1LD3 0000 HG35 4LD3 0000 HG35 6LD3 0000 HG35 9LD3 0000 HG50 1MD1 0000 HG50 4MD1 0000 HG50 6MD1 0000 HG50 9MD1 0000 HG50 1MD2 0000 HG50 4MD2 0000 HG50 6MD2 0000 HG50 9MD2 0000 HG50 1MD3 0000 HG50 4MD3 0000 HG50 6MD3 0000 HG50 9MD3 0000 HG60 1PD1 0000 HG60 4PD1 0000 HG60 6PD1 0000 HG60 9PD1 0000 HG60 1PD2 0000 HG60 4PD2 0000
21. s per minute Volts 120 208 240 277 480 600 Amps 150 140 135 130 120 120 Note Watlow recommends that ring terminal lugs be i used on all binding head screw terminals Note The 150 Amp relay HG2M XADX is not UL or CSA approved Note When replacing Watlow MD style relays UL listed to 480V ac CSA certified to 600V ac UL listed to 480V ac UL listed and CSA certified to 600V ac To prevent the MDR from rupture in the event of a heater short circuit you should always fuse the MDR load circuit Watlow recommends a Bussmann type JJN or JJS Class T fuse or equivalent Select a fuse size 1 25 times the connected load or the next size above but do not exceed 1 6 times the MDR rating To fuse the MDR field coil you can use Bussmann fuse number MDL 2 for coils up to 240V ac For coils up to 480V ac use Bussmann fuse number JJS 1 Watlow Series HG Mercury Displacement Relay User s Manual consider the HG60 model if larger gauge or multiple wires are required See the load termination specification above lt gt WARNING Install high or low temperature control protection in systems where an overtemperature or undertemperature fault condition could present a fire hazard or other hazard Failure to install temperature control protection where a potential hazard exists could result in damage to equipment and property and personal injury or death 6
22. th See page 6 for fusing recommendations A Use copper conductors only 1 Pole Wiring Example i Fuse L1 120V ac Hj o oO 1 Pole o 120V ac Coil Qe S Control L2 2 Neutral Heater 2 Pole Wiring Example Fuse Fuse 240V ac 3 Single L2 Phase Control ac 19 Heater 3 Pole Wiring Example 208V ac Li FUSes y ien 3 Phase 4 L2 Wye l3 A 1 3 Pole elelei 120V ac N Coil Ip S Ree BO ENT gt e i Control i CAJ I S S S 3 Phase Wye Heater Watlow Series HG Mercury Displacement Relay User s Manual 3 Field Coil Power Requirements HG30 XAAX 0000 1 Pole 2 Pole 3 Pole Voltage Current Power Current Power Current Power 24V ac NA NA 0 456A 10 9VA 0 510A 12 2VA 120V ac NA NA 0 121A 14 5VA 0 106A 12 7VA 208V ac NA NA 0 055A 11 4VA 0 055A 11 4VA 240V ac NA NA 0 063A 15 1VA 0 062A 14 9VA 24V dc NA NA 0 240A 5 8W 0 250A 6 0W HG30 XKDX 0000 HG35 XLDX 0000 HG50 XMDX 0000 HG60 XPDX 0000 1 Pole 2 Pole 3 Pole Voltage Current Power Current Power Current Power 24V ac 0 235A 5 6VA 0 529A 12 7VA 1 270A 30 5VA 120V ac 0 057
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