Relay Information

General Information

Mercury Relays (Mercury Contactors) are all designed and built to meet the most exacting demands of industry. They have won their high place in the electrical field by doing the tough and tricky jobs that ordinary equipment could at best do in an uncertain manner (especially resistive heating). They have proved their ability to stand up under the most adverse conditions of temperature, dust and moisture, in all types of applications. All the care required for the manufacture of high-grade instruments is used in the manufacture of the switches. All switch parts are specially cleaned, and contamination is avoided by use of tweezers, gloves, etc., when making assemblies.

Mercury Relays (Mercury Contactors) are hermetically sealed with high quality glass to metal seals.
The stainless steel tube is totally encapsulated in high grade UL approved epoxy to prevent moisture damage and voltage breakdown through the protective coating.
The coils are wound on compact nylon bobbins and molded onto the metal tube to provide minimum power loss. This allows for low coil power required to actuate the contactor. This also enables the units to handle high loads with minimum de-rating due to higher ambient temperatures.
Inert gases internally prevent excessive arcing between the mercury and the electrodes which enables the unit to function for millions of cycles with very low contact resistance, and minimum deterioration of the internal parts.
Available in all standard coil voltages, in single pole, two pole and three pole arrangements. Other coil voltages available upon request.
In multiple pole units each tube is actuated by its own coil. This eliminates pull-in variation between contact tubes, assuring consistent switching.

Features

  1. ADVANTAGES OVER ELECTROMECHANICAL AND SOLID STATE RELAYS
    1. Superior Performance and Reliability
      1. Long life
      2. Durable
    2. Compact Size
    3. Low, Predictable Contact Resistance
    4. Reduced RFI for Improved Interface Capability
    5. Handles a Variety of Loads
      1. Increases design flexibility
    6. Rapid On-Off Cycling Capability
      1. Mercury quickly dissipates contact heat
    7. Low Coil Power Requirements
    8. Minimal Derating Due to Higher Ambient Temperatures
    9. Quiet Action
  2. DESIGN and CONSTRUCTION
    1. Contacts are within a hermetically sealed steel body
      1. Impervious to adverse conditions
      2. No external arcing
    2. Arcing is in a gaseous atmosphere
      1. Quenches the arc
      2. Extends relay life
    3. Only one moving part (the plunger)
      1. No buttons to pit, weld or burn out
    4. One coil for each set of contacts
      1. Assures consistent switching
      2. Minimizes pull-in variation between contacts
    5. Epoxy encapsulated
      1. Moisture resistant
      2. High dielectric strength
      3. Permanently fixes contacts to coil; eliminating possible misalignment
      4. Helps dissipate heat and noise
      5. Rugged (impact resistant)
  3. BENEFITS
    1. Reduction of Operational and Maintenance costs
    2. Increases Utilization and Productivity of Equipment
      1. By reducing down-time
    3. Installation and service is a routine operation
      1. Simple to install
      2. No sophisticated equipment is required
      3. Easy to trouble-shoot

Typical Applications For Mercury Relays (Mercury Contactors)

LIGHTING
Auditorium Lighting
Copy Equipment
Dimmer Controls
Display Signs
Emergency Lighting
Flood Lights
High Intensity Lamps
Hospital Lighting
Lighting Test Panels
Mercury Vapor Lamps
Parking Lots
Photography Lighting
Scoreboards
Sodium Vapor Lamps
Stage Lighting
Street Lighting
Tower Control
Traffic Signal
Tungsten Lamps
GENERAL APPLICATIONS
Air Conditioning
Alarm Systems
Automatic Door Closers
Battery Chargers
Blue Print Machines
Copiers
Computer Power Supplies
Corrosive Locations
Dusty, Oily Locations
Dry Cleaning Equipment
Energy Management Systems
Farm Incubators and Brooders
High Cycle Rate Applications
Low Voltage Switching
Marking Equipment
Engraving Equipment
Motor Starting
Soldering Systems
Telephone Switching
Test Panels
Vapor De-greasers
X-Ray Machine Controls
ELECTRIC HEATERS
Baseboard Heaters
Blow Molding
Cabinet Heaters
Chemical Tank Heaters
Curing Furnaces
Drying Ovens
Duct Heaters
Film Packaging
Glass Furnaces
Heat Lamps
Heat Sealing Machines
Induction Heater
Industrial Ovens
Infrared Heaters
Ink Drying
Ink Heating
Injection Molding Machines
Kilns
Lab Ovens
Packaging Equipment
Plastic Extruder
Quartz Heaters
Radiant Heaters
Roof Top Heating
Shrink Tunnels
Unit Heaters
Vacuum Forming


FOOD INDUSTRY EQUIPMENT (HEATERS)
Baking Ovens
Coffee Urns
Deep Fryers
Dishwashers
Electric Grills
Electric Ranges
Pizza Ovens
Steam Generators


SPECIALTY APPLICATIONS
Capacitor Discharge Systems
Hazardous Locations
Phase Converters
Tower Control

Description

MERCURY TO METAL CONTACTOR:
The mercury relays (mercury contactors) load terminals are isolated from each other by the glass in the hermetic seal. "The plunger assembly", which includes the ceramic insulator, the magnetic sleeve and related parts, floats on the mercury pool. When the coil is powered causing a magnetic field, the plunger assembly is pulled down into the mercury pool which is in turn displaced and moved up to make contact with the electrode, closing the circuit between the top and bottom load terminal, which is connected to the stainless steel can.

To make the unit function as a "Hybrid" time delay, we add a solid state circuit to the coil to delay the power to the coil.

For constant duty applications, a return spring is used in place of the buffer spring. Contact the factory.

30 AMP Normally Open Mercury Relays (Mercury Contactors)

General Information:
The 30 AMP model is designed to save space and simplify mounting methods. The standard mounting bracket on the three pole model allows the unit to be mounted in standard 3" snap track channel. If you do not use snap track mounting, the standard three pole bracket has key hold slots for easy mounting in any panel arrangement. The universal three pole mounting bracket has various mounting holes and key hole slots to meet a variety of mounting centers.

The 30 AMP series is a more compact line with a well proven switch, which is the heart of mercury relays. It is the same switch design that is in our 35 and 60 AMP encapsulated MDRs, which have withstood the test of time and millions of cycles in many different applications.

Typical Specifications:

  • On Normally Open Units:
    • Operate Time: 50 milliseconds
    • Release Time: 80 milliseconds
  • Contact Resistance: 30 AMP = .003 ohm *
  • Dielectric Withstant: 2500 VAC RMS
  • Longevity: Millions of Cycles
  • Temperature Range: -35 degrees C to 85 degrees C
  • Coil Terminals:
    #6 Binding Head Screws Torque to 7 IN-LB
  • Load Terminals: #8 Binding Head Screws
  • UL Listing: File #E62767
  • C.S.A.: File #LR41198
    • Exceeds 5000 VAC RMS across the contacts

* After Cycling Under Load

Coil Data

Catalog No. Res. (Ohms) Current (MA) VA Watts
30NO-24D
230NO-24D
330NO-24D

30NO-24A
230NO-24A
330NO-24A

30NO-120A
230NO-120A
330NO-120A

30NO-220A
230NO-220A
330NO-220A
180
131
73

28
12.5
7.6

725
317
210

3,150
1,300
728
133
188
329

316
610
815

65
118
163

27
56
86
3.2
4.5
7.9

7.6
14.6
19.6

7.8
14.2
19.6

6.0
12.3
18.9
3.2
4.5
7.9

2.8
4.7
5.0

3.1
4.4
5.6

2.2
4.1
5.5


RATINGS
(Ratings are in amps unless otherwise specified.)


Type of Loads Voltage 30NO



A.C. Resistive



A.C. IND. P.F. .4 OR GREATER



GENERAL PURPOSE P.F. .7
OR GREATER


D.C. RESISTIVE HEATING




TUNGSTEN LAMP

SINGLE PHASE
MOTOR LOADS


THREE PHASE
MOTOR LOADS

240V
480V
600V

120V
240V


240V
480V


48V
125V
250V


120V

120V
240V


240V
480V
30
30
30

-
-


-
-


-
-
-


-

-
-


-
-

35/60-AMP Normally Open Mercury Relays (Mercury Contactors)

Typical Specifications:

  • On Normally Open Units:
    • Operate Time: 50 milliseconds
    • Release Time: 80 milliseconds
  • On Normally Closed Units:
    • Operate Time: 30 milliseconds
    • Release Time: 35 milliseconds
  • Contact Resistance:
    • 35-AMP = .003 ohm *
    • 60-AMP = .002 ohm*
  • Dielectric Withstand: 2500 Vac Rms
  • Longevity: Millions of Cycles
  • Temperature Range: -35 degrees C to 85 degrees C
  • Coil Terminals:
    #6 Binding Head Screws Torque to 7 IN-LB
  • Load Terminals:
    Pressure Connectors for 4 - 14 AWG on 35-AMP Units Torque to 31.5 IN-LB
    2 - 8 AWG on 60-AMP Units Torque to 45 IN-LB
  • UL Listing: File #E62767 for 35 and 60-AMP N.O. Units 1-4 Poles
  • C.S.A.: File #LR41198 for 35 and 60-AMP N.O. Units (Heater Loads) 1-3 Poles
    • Exceeds 5000 VAC RMS across the contacts

* After Cycling Under Load

RATINGS
(Ratings are in amps unless otherwise specified.)

Type of Loads
A.C.
RESISTIVE



A.C.IND. P.F.
.4 OR GREATER


GENERAL PURPOSE
P.F. .7 OR GREATER


D.C.
RESISTIVE HEATING



TUNGSTEN LAMP


SINGLE PHASE
MOTOR LOADS


THREE PHASE
MOTOR LOADS

240V
480V
600V


120V
240V


240V
480V


48V
125V
250V


120V


120V
240V


240V
480V
35NO
35
35
35


-
-


-
-


-
-
-


35


1H.P.
1H.P.


-
-
35NO(H)
35
35
-


25
15


-
-


35
16
12


35


2HP
3HP


5HP
7.5HP
35NC
35
35
-


25
15


35
35


35
16
12


35


2HP
3HP


5HP
7.5HP
60NO
60
60
48


-
-


-
-


-
-
-


60


-
-


-
-
60NO(H)
60
60
-


30
20


60
60


60
40
20


60


3HP
5HP


7.5HP
10HP
60NC
60
60
-


30
20


60
60


60
40
20


60


3HP
5HP


7.5HP
10HP

100-AMP Mercury Relays (Mercury Contactors)

Typical Specifications:

  • On Normally Open Units:
    • Operate Time: 50 milliseconds
    • Release Time: 80 milliseconds
  • On Normally Closed Units:
    • Operate Time: 45 milliseconds
    • Release Time: 60 milliseconds
  • Contact Resistance: .001 ohm *
  • Dielectric Withstand: 2500 Vac Rms
  • Longevity: Millions of Cycles
  • Temperature Range: -35 degrees C to 85 degrees C
  • Coil Terminals:
    #6 Binding Head Screws Torque to 7 IN-LB
  • Load Terminals:
    Pressure Connectors for 2 - 8 AWG Torque to 45 IN-LB
  • Load Terminals:
    Pressure Connectors. Standard Accepts 2 to 12 AWG. For 1 to 8 AWG Torque to 45 IN-LB, Add Suffix -5 to Catalog No. (I.E. 100NO-120A-5)
  • Ratings: Derate over 240 Vac Res.
    • Exceeds 5000 VAC RMS across the contacts

*After Cycling Under Load

RATINGS
(Ratings are in amps unless otherwise specified.)


Type of Loads Voltage 100NO 100NO(H) 100NC

A.C. RESISTIVE 240V 100 100 100
480V 80 80 80
600V 70 70 70

A.C. IND.
P.F. .4 OR GREATER
120V - 100 100
240V - 100 100

GENERAL PURPOSE
P.F. .7 OR GREATER
240V - 100 80
480V - 80 80

D.C. RESISTIVE HEATING 48V - 100 100
125V - 50 50
250V - 30 30

TUNGSTEN LAMP 120V 100 100 100

SINGLE PHASE MOTOR LOADS 120V - 7.5HP 7.5HP

DOUBLE PHASE MOTOR LOADS 240V - 10HP 10HP

THREE PHASE MOTOR LOADS 240V - 15HP 15HP
480V - 20HP 20HP

"S" 100 AMP Mercury Relays (Mercury Contactors)

Typical Specifications:

  • On Normally Open Units:
    • Operate Time: 50 milliseconds
    • Release Time: 80 milliseconds
  • On Normally Closed Units:
    • Operate Time: 45 milliseconds
    • Release Time: 60 milliseconds
  • Contact Resistance: .001 ohm *
  • Dielectric Withstand: 2500 Vac RMS
  • Longevity: Millions of Cycles
  • Temperature Range: -35 degrees C to 85 degrees C
  • Coil Terminals: #6 Binding Head Screws Torque to 7 IN-LB
  • Load Terminals: Pressure Connectors. Standard Accepts 1 to 8 AWG Torque to 45 IN-LB
  • Ratings: Derate over 480 VAC Res.
    • Exceeds 5000 VAC RMS across the contacts

* After Cycling Under Load

Type of Loads Voltage "S" 100NO "S" 100NO(H)

A.C. RESISTIVE 240V 100 100
480V 100 100

GENERAL PURPOSE
P.F. .7 OR GREATER
240V 100 100
480V 100 100

High Voltage Relays High Voltage Contactors

For UV Curing, and Various High Voltage applications. Available in Single Pole, Normally Open, and Normally Closed Units. The coils utilize 6-32 Wire Binding Screws, and the Contacts use Compression type terminals for 4 thru 14 AWG wire.
Ratings are: 10 Amps @ 3,500 VAC
15 Amps @ 2,500 VAC
AC Inductive - Power Factor .7 or Greater

  • Exceeds 5000 VAC RMS across the contacts
Catalog Number Coil Voltage Resistance Current Draw Wattage V.A.
100NC-24D-6A 24VDC 121 198 ma 4.8 4.8
100NC-120A-6A 120VAC 380 125 ma 5.9 15.0
100NC-220A-6A 220VAC 1,400 76 ma 8.1 16.7
100NO-12DH-6A 12VDC 16 750 ma 9.0 9.0
100NO-24AH-6A 24VAC 16 760 ma 9.2 18.2
100NO-24DH-6A 24VDC 65 370 ma 8.9 8.9
100NO-120AH-6A 12-VAC 380 158 ma 9.5 19.0
100NO-220AH-6A 220VAC 1,400 90 ma 11.3 19.8

Coil Data Per pole ratings on standard coils

Catalog Number Voltage Resistance
(D.C. Ohms)
Current
(Milli-amperes)
Volt Amperes
(V/A)
Power
(Watts)
35NO-24A 24VAC 50 242 5.8 2.9
35NO-120A 120VAC 1,250 53 6.4 3.5
35NO-208A 208VAC 3,400 30 6.2 3.1
35NO-220A 220VAC 4,800 28 6.2 3.8
35NO-277A 277VAC 7,900 20 5.5 3.2
35NO-480A 480VAC 20,000 12 5.9 3.0

35NO-6D 6VDC 13 462 2.8 2.8
35NO-12D 12VDC 36 333 4.0 4.0
35NO-24D 24VDC 176 136 3.3 3.3
35NO-48D 48VDC 636 75 3.6 3.6
35NO-125D 125VDC 3,400 37 4.6 4.6
35NO-250D 250VDC 14,800 17 4.2 4.2

35NC-24A 24VAC 36 310 7.4 3.5
35NC-120A 120VAC 860 65 7.8 3.6
35NC-220A 220VAC 3,400 31 6.8 3.3

35NC-12D 12VDC 36 333 4.0 4.0
35NC-24D 24VDC 176 136 3.3 3.3
35NC-48D 48VDC 560 86 4.1 4.1
35NC-125D 125VDC 3,400 37 4.6 4.6

60NO-24A 24VAC 50 259 6.2 3.4
60NO-120A 120VAC 1,250 48 5.8 2.9
60NO-208A 208VAC 3,400 30 6.2 3.1
60NO-220A 220VAC 4,800 27 5.9 3.5
60NO-277A 277VAC 7,900 19 5.3 2.9
60NO-480A 480VAC 20,000 12 5.8 2.9

60NO-12D 12VDC 36 333 4.0 4.0
60NO-24D 24VDC 176 136 3.3 3.3
60NO-48D 48VDC 636 75 3.6 3.6
60NO-125D 125VDC 3,400 37 4.6 4.6
60NO-240D 250VDC 14,800 17 4.3 4.3

60NC-24A 24VAC 36 325 7.8 5.3
60NC-120A 120VAC 860 69 8.3 4.1
60NC-220A 220VAC 3,400 34 7.5 3.9
60NC-277A 277VAC 7,900 26 7.3 5.5

60NC-12D 12VDC 36 333 4.0 4.0
60NC-24D 24VDC 140 171 4.1 4.1
60NC-48D 48VDC 560 86 4.1 4.1
60NC-125D 125VDC 3,400 37 4.6 4.6

100NO-24A 24VAC 16 646 15.5 6.7
100NO-120A 120VAC 380 137 16.4 7.1
100NO-220A 220VAC 1,400 73 16.1 7.5
100NO-277A 277VAC 2,400 55 15.2 7.3
100NO-480A 480VAC 6,300 35 16.8 7.7

100NO-24D 24VDC 65 369 8.9 8.9
100NO-48D 48VDC 350 137 6.6 6.6
100NO-125D 125VDC 2,400 52 6.5 6.5

100NC-24A 24VAC 16 515 12.4 4.2
100NC-120A 120VAC 380 110 13.2 4.6
100NC-208A 220VAC 1,400 55 11.4 4.2
100NC-240A 240VAC 1,685 49 11.8 4.0
100NC-480A 480VAC 6,300 27 13.0 4.6

100NC-12D 12VDC 28 433 5.2 5.2
100NC-24D 24VDC 121 198 4.8 4.8
100NC-48D 48VDC 380 126 6.1 6.1
100NC-125D 125VDC 2,400 52 6.5 6.5

Notes:

  1. Inrush Current=1.5 times the steady state current. (No inrush on DC coils).
  2. Minimum operating voltage 90% of nominal voltage.
  3. All A.C. voltages are at 50/60 Hz.
  4. For other coil voltages, contact factory.
  5. Ratings shown are per pole (Coils are in parallel).

Proper Fusing is Required

While MDIs contactors handle high inrush, such as lamp loads, very well, mercury contactors are susceptible to damage by short circuit currents, and should be fused to minimize short circuit fault currents. Fast acting UL class RK-1 and class J fuses and semiconductor I2t fuses more effectively protect relays than other fuses. These are low-peak fuses designed to limit short circuit currents. Regardless, when there is a short circuit, relay operations should be closely monitored afterward because of the possibility of concealed damage that could cause the relays to behave inconsistently.

RECOMMENDED

250VOLT 600VOLT
KTN-R KTS-R
JJN/A3T JJS
JKS/A4J
KTK-R
  • Mercury Displacement relays must mount vertically +/- 10 degrees.
  • Control line can be protected with metal oxide varistor (MOV). Use suffix -11.
  • Disconnect power before installing or servicing. Observe all electrical and safety codes and ordinances such as National Electrical Code (NEC) and the Occupational Safety and Health Act (OSHA).