MARS 19006 Mars 67 Potential Relay Instruction Manual

1. Product Overview

The MARS 19006 Mars 67 Potential Relay is a non-positional electrical component designed for use in refrigeration machine applications. This relay is engineered to replace a wide range of original equipment manufacturer (OEM) models, offering broad compatibility.

Key features include:

• Genuine MARS Quality: Designed to replace numerous OEM models.
• Non-Positional Operation: Allows for flexible mounting orientations.
• QC-6 Kit Included: Facilitates conversion from screw-on to push-on terminals.
• Universal Break-Off Bracket: Features a versatile mounting bracket with snap-off parts for customization.

Each relay includes detailed instructions and a wiring diagram to assist with proper installation.

An image showing the MARS 19006 Mars 67 Potential Relay. The relay is a light gray rectangular block with a metallic mounting bracket attached to its top and sides. Markings on the side of the relay include '3ARR3MARS67', 'M&A 19006', a wiring diagram with terminals 1, 2, and 5, and 'MADE IN MALAYSIA'. The bracket features multiple screw holes for versatile installation.

2. Safety Information

Before installing or servicing the MARS 19006 Potential Relay, please read and understand all safety instructions. Failure to follow these instructions may result in property damage, serious injury, or death.

• Disconnect Power: Always ensure that the main power supply to the refrigeration unit is disconnected before beginning any installation or maintenance work.
• Qualified Personnel: Installation and servicing should only be performed by qualified and experienced technicians.
• Electrical Hazards: Be aware of potential electrical shock hazards. Do not touch live wires or terminals.
• Proper Wiring: Follow all wiring diagrams and local electrical codes. Incorrect wiring can lead to malfunction or hazards.
• Component Compatibility: Ensure the relay is compatible with the voltage and current requirements of the system it is being installed into.

3. Setup and Installation

The MARS 19006 Potential Relay is designed for straightforward installation. Each unit includes a QC-6 kit for terminal conversion and a universal break-off bracket for flexible mounting.

3.1 Preparation

1. Power Disconnection: Turn off and lock out the main power supply to the refrigeration system. Verify power is off using a multimeter.
2. Identify Existing Relay: Locate the relay to be replaced. Note its wiring configuration and mounting method.
3. Review Wiring Diagram: Refer to the wiring diagram included with your MARS 19006 relay for specific connection details.

3.2 Mounting the Relay

1. Bracket Customization: The universal break-off bracket can be adjusted to fit various mounting points. Carefully snap off any parts of the bracket that are not needed for your specific installation.
2. Secure Mounting: Mount the relay securely using screws through the holes in the bracket. Ensure the relay is stable and will not vibrate loose during operation.

3.3 Wiring Connections

1. Terminal Conversion (if needed): If your application requires push-on terminals, use the provided QC-6 kit to convert the screw-on terminals on the relay. Follow the instructions provided with the QC-6 kit.
2. Connect Wires: Connect the system wires to the appropriate terminals on the MARS 19006 relay as indicated by the included wiring diagram. Ensure all connections are tight and secure.
3. Verify Connections: Double-check all wiring against the diagram to prevent misconnections.

3.4 Post-Installation

1. Secure Wiring: Ensure all wiring is neatly routed and secured to prevent accidental dislodgement or damage.
2. Restore Power: Once installation is complete and verified, restore power to the refrigeration system.
3. Test Operation: Observe the system's operation to confirm the relay is functioning correctly.

4. Operation

The MARS 19006 Mars 67 Potential Relay operates automatically within the refrigeration system. Its primary function is to control the starting winding of a single-phase motor, typically found in compressors. When the motor starts, the relay senses the back electromotive force (EMF) generated by the motor's running winding. Once this back EMF reaches a predetermined level, indicating the motor has reached sufficient speed, the potential relay disconnects the starting winding from the circuit.

This ensures that the starting winding is only energized during the brief startup phase, preventing overheating and damage to the motor. The relay will re-engage the starting winding when the motor attempts to start again after a stop cycle.

5. Maintenance

The MARS 19006 Potential Relay is designed for reliable, long-term operation with minimal maintenance. However, periodic inspection of the relay and its connections is recommended as part of routine system maintenance.

• Visual Inspection: Periodically inspect the relay for any signs of physical damage, discoloration from overheating, or loose connections.
• Terminal Integrity: Ensure all wire connections to the relay terminals remain tight and free from corrosion. Loose connections can lead to arcing and premature failure.
• Cleanliness: Keep the area around the relay clean and free from dust, dirt, or moisture, which can interfere with its operation or cause short circuits.
• Replacement: If the relay shows signs of failure (e.g., motor not starting, humming, or tripping circuit breakers), it should be replaced with an identical MARS 19006 unit.

Always disconnect power before performing any inspection or maintenance.

6. Troubleshooting

If the refrigeration system experiences issues related to motor starting, the MARS 19006 Potential Relay may be a contributing factor. Here are some common troubleshooting steps:

• Motor Hums but Doesn't Start: This often indicates that the starting winding is not engaging or disengaging correctly. Check the relay's connections and verify its internal operation.
• Motor Starts Slowly or Trips Breaker: This could suggest the starting winding is remaining engaged for too long, or the relay contacts are welded shut.
• No Motor Action: Ensure the relay is receiving power and that its internal contacts are making proper connection when required.
• Visual Inspection: Look for burnt terminals, melted plastic, or other visible damage on the relay.
• Continuity Test: With power disconnected, use a multimeter to test continuity across the relay's contacts according to the wiring diagram. This can help identify if the contacts are stuck open or closed.

If troubleshooting indicates a faulty relay, replace it with a new MARS 19006 unit. Do not attempt to repair a damaged relay.

7. Specifications

8. Warranty and Support

For information regarding warranty coverage and technical support for your MARS 19006 Mars 67 Potential Relay, please refer to the documentation provided with your purchase or contact MARS customer service directly. Keep your proof of purchase for warranty claims.

Manufacturer: MARS - Motors & Armatures, Inc.