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1. additional capacitor to set switching time State 0 output relay off green lamp optical level switch is on above the nominal value as per Item 4 Sz contacts 7 8 closed Rd additional range resistor l l Note for DPZ 2Rzp version the colours of the optical level Rs control resistance e g PTC thermistor photoresistor switches are opposite microcontacts etc Zs control impedance e g electrodes in liquid c Nominal switching resistance values Median switching resistance coverter sensitivity threshold range Rps Rps KQ 7 5 Rd kQ 30 for Rd lt 100kQ for Rd gt 100kQ Rps is not normalized Limit enabling resistance Rzg and limit disabling resistance Rwg for Rd lt 100 kQ Rwg kQ Rps kQ x 1 3 4 20 Rzg kQ Rps kQ x 0 7 20 for Rd Rwg 4MQ 50 Rzg 2 2 MQ 50 6 2 2 Circuit to signal the liquid level drop below the permissible minimum level Description once the liquid level has dropped below the minimum states of the output contacts 6 7 8 are as presented in the figure 1 e they are the same as when no power is present at terminals Nos 4 5 Used 1 a to protect pumps from dry run protect and control steam boilers Special converter DPZ 2Ropz can be supplied for deep well pumps with delayed pump restart Multiple signalling circuits of that type can be used in one vessel 6 6 2 3 Non inversion type circuit to signal the preset impedance or2. application circuits are the same this simplifies the selection of the Rd resistor The flip flop Wp controls the output electromagnetic relay P including 1 pair of switching contacts constituting a voltage free output of the entire level switch and controls the signal lamps optical level switches The red lamp Sc goes on when the electromagnetic relay is energized while the green lamp Sz goes on to indicate that the relay is de energized it is the other way round for DPZ 2Rzp version 3 The possibility to swap the range resistor and the sensor impedance in the measuring divider circuit allows a free selection of one of the above application circuits by the user The minimum level signalling circuit Fig 4 enables the output relay once the level exceeds the required minimum The circuit is suitable to indicate the minimum level because the drop of the liquid level in the tank below the required minimum level results in a state of output terminals identical to that when no power is present which causes that any possible power failure is indicated as an emergency and so is the drop of the liquid level below the warning minimum level The operation of the circuit shown in Fig 5 is opposite The consequence of such solutions is a simplification of the level switch and high reliability The converter is a universal block of permanent unchanged parameters the features and parameters of which can be adjusted over a wide range by the user v
3. most of the applications Auxiliary alternative voltage Up is derived from the secondary winding of the separating transformer Tr and supplied to a measuring divider formed of an internal range resistor Rzk and an external range resistor Rd and the measured impedance of the CZP 1sensor The divider tap is connected to the input of the detecting amplifier Wd The control impedance that co forms the measuring divider the impedance of the CZP 1sensor has an impact depending on its value on the level of the alternating output voltage of the detecting amplifier Wd and hence it correspondingly biases the flip flop Wd The control impedance values for which the relay states are changed equal to switching resistance values are a result of the total value of the internal range resistor Rzk and the additional range resistor Rd and optionally an additional reducing resistor Rdr connected to the terminals 2 11 The value of the internal range resistor Rzk 7 5 kQ is selected so as to allow the level switch to meet the requirements of the most of typical applications with a zero value of the additional external range resistor Rd The flip flop switching points expressed as switching resistance values are selected in such a way that their average arithmetic value median threshold for both basic application circuits Fig 4 and 5 is approximately the same Consequently the switching resistance values for a specified Rd value for both
4. or its assemblies are components intended for signalling and control systems Before they are used a relevant technical design must be prepared to associate the level switch with the object and other components indispensable for the performance of the necessary functions The design should be prepared by a specialist e g an electrician holding the necessary licenses Both the design and the execution must meet the requirements and recommendations indicated in this manual and the requirements and recommendations of the regulations in force for the individual object The circuit made according to the design should guarantee the safety of people animals property and environment 2 Operation The operation of the level switch is based on the impact of the of the sensor electrode with the electricity conducting medium on the electric resistance impedance of that electrode against the container walls or the counterelectrode 3 Design SPC 1K level switch is a selected set composed of an electrode level sensor CZP 1 type Fig 3 and a two state impedance converter DPZ 2R type feeder relay Fig 2 Sensor Fig 3 has a casing with taper pipe or metric thread A special electrode is embedded in the casing properly isolated from the casing with a thread clamp for connecting a conductor The clamp is shielded with a heat resistant flexible cap 6214 k stainless steel R 1 4 Ins Watton anal karripe red relay energized green r
5. reducing resistor Rdr The 12V DC and 24V DC versions are equipped with electrical isolation from the power supply for those versions the of the power supply must be connected to terminal 5 while the must be connected to 4 Stub pipes with G1 4 or M 20x1 5 threaded holes can be supplied for the sensors to be welded in For CZP 1 35 sensor which replaces the no longer used SK 35 probe the electrode length is L 60mm extended with an additional EKD 1 electrode Sensitivity switching 7 5 kQ Rd see Tab 1 Electrode diameter 4 threshold 5 Recommendations for installation and safety of use A caution Any works can be performed after this manual and the design referred to in Item 1 have been carefully read The principles given in the manual and design must be followed Non compliance with the said principles may result in electric shock to persons and or damage to the equipment Install the converters in cabinets or boxes which meet the requirements of the safety standards so that the terminals and other components connected to dangerous voltage are efficiently shielded preventing the occurrence of the dangerous voltage on the conductive components accessible to people and animals connect metal cabinets or enclosures and other conductive components to the protective conductor Connect the metal tank and or the ground electrode to the protective conductor also Caution Impedance of protective connect
6. signalling circuits can be used in one vessel at a time 6 2 7 Parameter limiter circuit for minimum level 6 2 5 Water level control performed by filling with minimum level signalling 6 2 6 Water level control performed by emptying with maximum level signalling EEL l E Olli al E calles H chet hil H hax level J I i Ii I l l power supply am CeP 1 ARK 7 AY Power supply EG eet H Jon ton em PN etic bho 2 zi zmax i eel of the limiter a o L1 T pede aE 1 mir H s L1 eee Se PEH a alle 3 a ce a Eg ie 3 oc PEH P_M 7 Typical values of the additional range type Rd resistor for various liquid types and distances between the sensor and the converter for operation with CZP 1 type sensor are listed in Table 1 The Rd values given in Table 1 are not critical and can be changed to intermediate values according to the actual requirements conductivity of the liquid and the liquid pollution level In normal conditions it is sufficient to use Table 1 Table 1 Liquid Rd value Maximum length Liquid type conductivity KQ of the line connecting Comments the sensor with the converter CG ee ee eee eee ordinary clean water basic juices acids bases salts measurement etc 2 rainwater milk waste water etc only for 4 distilled water arrangement as per Fig 4 only for distilled water ar
7. tank walls should be followed this does not apply to the ground electrode which if used may contact the tank wall Where long electrodes are necessary with no possibility to increase the distance between them sensors with extended insulation must be ordered If the electrodes and or terminals are accessible to people and or pets guard them with protective cover or use converters powered with safe voltage 12V DC or 24 V DC or 24V AC alternatively whole of the power must be supplied via protective differential switch Connect the sensors with the converters using 250V cables with Cu strands of cross section 21 5 mm For temperatures above 100 C use silicone or teflone coated conductors with heat resistant strands e g nickel plated strands In damp places or where vapours are present e g in intermediate pumping stations thoroughly apply silicone grease on the terminal and the strand before pulling the rubber cap home Protect the ground connection reliably against corrosion the length of cables between the sensor and the converter may be from 1 m to 500 m and over depending on the conductivity of the liquid additional resistor RD and the noise level Typical values of maximum distances are listed in Table 2 Where longer cables are necessary with the liquid being of good conductivity 1 mS cm the sensitivity can be reduced by connecting an additional reducing resistor Rdr to the terminals Nos 2 11 of the DPZ 2R converter In such a cas
8. the electrode the sensor must be cleaned periodically e g with cleaning agents intended for sanitary facilities cleaning must be performed in such a way as not to damage the insulation In more difficult conditions when problems are encountered during the start up of the level switch due to adverse conditions high temperature heavy pollution caustic medium severe interference etc seek the advice of the manufacturer Typical time delay values t based on the additional Cd capacitor capacitance set through stepwise change of sensor impedance from zero to infinity or the other way round are given in Table 2 Table 2 4Tu 100p 220 1000y the Table is not applicable for DPZ 2Rzw and DPZ 2Rsw versions DPZ 2R converters can also be used for other applications e g as time elements contact thermometer or contact manometer switching capacity amplifiers also for liquid thermometers and manometers with built in contacts electrodes automatic light sensitive switches power outputs controlled with TTL CMOS see example in 6 2 2 etc as motor overheating protectors combined with PTC thermistors and other DPZ 2R converters can also operate as level level switches with any other level sensors probes of conductometric conductance types Where very strong interference is present e g in direct vicinity of high power inverters or if the distance between the converter and the tank is significant including tanks with very low conductivi
9. 4 6xDPZ 2R 6 pieces of PG11 r A a A CZP 1 MK20x1 5 1m chokes A i v CZP 1w R1 4 1m 200x400x130 180 x 380 CZP 1w MK20x1 5 Im 8xDPZ 2R 10 pieces of PG11 chokes Views of various versions of SPC level switch assemblies Multi line block data 3xDPZ 2R Note There is a possibility to provide ready made assemblies incl contactors in box enclosures see above designed to perform defined functions e g level adjustment and signalling of minimum level Control valves and pumps can also be supplied to form a set 8 Warranty Warranty is granted for the period of 12 months from the date of purchase according to the general rules Justified claims if any will be handled after the product has been delivered to the manufacturer or distributor 9 Declaration of conformity C The manufacturer declares that the product conforms to the essential requirements of the low voltage directive 73 23 EC and in particular the standard PN EN 61010 1 1999 A2 1999 and the directive 89 336 EC on electromagnetic compatibility and in particular the standards PN EN 55014 1 and PN EN 55014 2 respectively harmonised with those directives The manufacturer reserves the right to modify the product Ei www tme eu Transfer Multisort Elektronik Headquarters Poland 93 350 Lodz ul Ustronna 41 correspondence address 90 951 Lodz 40 PO BOX 2071 Tel 48 42 645 54 44 fax 48 42 645 54 70 e mail export tme eu VAT ID PL7290108984 REGON N
10. ACE 473171710 District Court for L6dz Sr dmiescie NCR 0000165815 initial capital 3 300 000 PLN
11. Level switches controllers for liquid levels limit states and other physical quantities type SPC 1K including DPZ 2R two state impedance converters relays and CZP 1 electrode level sensors probes User s manual No 060323MCE Edition 25 04 2006 acc to 040430_09 11 2004 An PN aa rl A H th o gt Q O Level sensors probes Fig 1 SPC 1K level switches view of selected unit types 1 Application SPC 1K level switches are intended for use in signalling circuits and or control of levels of media such as water waste water pulps syrups emulsions chemicals drinks milk coal wet sand and soil moulding sand farm produces etc Do not use for fuels oils places where explosion hazard is present etc Intended for use in facilities such as wells pipelines reactors and chemicals containers sink basins and water discharge basins intermediate pumping stations and oil traps for waste water rooms with threat of flooding pressure expansion vessels boilers autoclaves silos etc The converters are intended for permanent incorporation into protective cabinets or housings while the sensors are designated for permanent installation in the unit where the medium level or presence or absence is to be signalled Detailed circuit and environmental conditions in which the level switch can be used are based on the further information and parameters to be followed The level switch and
12. ater level controller circuits If the level switch is not used to perform the a m function of a protective equipment subjected to the pressure equipment directive 97 2 CE the above limitations are not necessary and it is sufficient to ensure the sensor mounting method described earlier in this text Where CZP 1 sensors are used for clean liquids they can be even installed at the vessel bottoms with the electrode directed upwards vertically or at an angle but in any such case this must be agreed with the sensor manufacturer who must be provided with the information on the liquid type and other mounting conditions as the electrode insulation must be adequately adapted for such installation method because the level indication is performed at the insulation edge on the electrode 6 Level switch applications 6 1 Steam boilers see Fig 4 and 5 or 6 2 5 6 2 6 6 2 7 6 2 Other applications 6 2 1 Inversion type preset impedance value signalling circuit minimum level signalling circuit a Connection diagram b General characteristics DPZ R Output state Cd 37 7TTTT E 2 T i Sig 0 in f To DE m 5 l RS ZS N Ti T Gi Z oz ar RS 25 c F io HE Rd g a 4 L oo Rd 0 L g ea Sc red lamp optical level switch State 1 output relay on red lamp optical level switch is on SZ green lamp optical level switch Sc contacts Nos 6 8 closed Cd
13. current value a Connection diagram b General characteristics DP 2R Output state Ca n e z 1 lio Sc 5 ae o Ea 5 i 7 Rd 41 Fi id 5 Rd 100k a h a H 2 p i US IS z 5 230 We US 3 c Sz 7 go Uwy Ups Ug 4 Ls gy Ipe Iza A Sc red lamp optical level switch Sz green lamp optical level switch Cd additional capacitor to set switching time above the nominal value as per Item 4 Rd additional range resistor State 1 output relay on red lamp optical level switch is on Sc contacts Nos 6 8 closed State O output relay off green lamp optical level switch is on Sz contacts 6 8 closed Note for DPZ 2Rzp version the colours of the optical level US control voltage e g output signal from ciruits e g TTL switches are opposite CMOS etc c Nominal switching values and maximum permissible switching values for Rd Uzg 2 5 V 50 Uwg 1 8 V 50 Ips lt 0 05 mA US lt 24V 6 2 4 Circuit to signal the liquid level rise above the permissible maximum level Description once the liquid level has risen above the maximum level states of the output contacts 6 7 8 are as presented in the figure 1 e they are the same as when no power is present at terminals Nos 4 5 Applicable 1 a to provide signals and locking action to prevent vessels from overfilling signal the flooding of rooms signal leakage of various substances Any number of
14. e the sensitivity Gin KQO is 7 5xRdr kQ 7 5 Rdr kQ Rd provided that Rdr 0 5 KQ For condensate and other liquids of poor conductivity such as e g distilled water deionized water oiled liquids etc or for indication of water under oil the version DPZ 2Rzpp is recommended high sensitivity and resistance to noise lengths of connections can be multiplied A Caution When designing the arrangement and lengths of connections the requirement of low impedance of protective circuits defined earlier must be taken into account Use SP 50 probes category card SP 50 to protect deep well pumps from dry run and DPZ 2R if one with Cd 2100uF If the liquid is sloshing and an increased time delay causes no interference to the operation of the facility we recommend to use Cd in order that the sloshing does not unnecessarily switch the converter and other devices asymmetric delay is possible in DPZ 2R sw and DPZ 2Rzw Additional components Rd Cd Rdr if necessary supplied to order must be attached to the converter terminals according to the above diagrams Connections of the entire level switch must be made as per the above examples while taking into account the a m A Note strands if more than one of the same diameter should be inserted into one terminal Caution All installation works must be carried out by adequately qualified persons holding the necessary licenses after they have carefully read the user s manual and the desi
15. elay de energized aleztroge stainless steel s z C ija Fig 2 Dimensions of DPZ 2R converter including PZ11 type Fig 3 Dimensions of CZP 1 R1 4 sensor Relpol socket basic version The design of the converter Fig 2 is of a block type with a multipin 11 pin block intended for standard 11 contact sockets PZ 11 socket of Relpol ary is required or other socket with identical arrangement of terminals and of not worse electrical parameters Schematic and block diagrams of the entire level switch in two basic application circuits and the application functions of those circuits are illustrated in figures 4 and 5 The electric circuit can be powered from 230V AC network or with 24V AC current terminals 4 5 or 12 or 24 V DC current via internal converter power supply terminal 4 5 Input circuits terminals 9 10 11 1 2 3 are isolated from the power supply by a low power separating transformer Tr also where DC is used The circuit includes a transistor based detecting amplifier Wd and a bistable amplifier Wp with hysteresis flip flop output control relay P and signal lamps optical level switches Sz and Sc The detecting amplifier Wd is interfaced with the bistable amplifier Wp by a delay element composed of a resistor Ro and a delay capacitor Co The switching delay can be increased using an external capacitor Cd The delay value without the use of the Cd capacitor is optimal for
16. gn referred to in Item 1 and after they have got acquainted with the product Conduct all electric works while the power is off Mount the sensors on unheated and depressurized vessels which contain no substances detrimental to health Caution According to the conditions of the Technical Inspection the sensors of the level switches which act as switches and parameter limiters in pressure equipment protective automation devices which are installed in steam boilers and other pressure vessels should according to the Technical Conditions of the Technical Inspection DT UC 90 WO A 02 be mounted vertically in an enclosure with balancing holes with the cylindrical part of the enclosure reaching min 10 mm below the electrode tip the smallest gap between the electrode and the enclosure being at least 5 mm examples see Fig 4 and 5 Caution When using the level switch or its components for the pressure equipment gt 0 5 bar which is subject to Directive 97 23 EC the said level switch must not be used as protective equipment above category I as per that directive or if used it must be approached as cooperative components to be subjected together with the final unit for certification for conformity with that directive as the manufacturer provides no declaration of conformity with that directive for procedural reasons this is how the level switch has been used for a number of years by e g steam boiler manufacturers in boiler limiter and w
17. ia an external connection and an attachable additional range resistor Rd an or reducing resistor Rdr and optionally an additional delay capacitor Cd Fig 4 Inversion type minimum level signalling circuit a Circuit diagram position of output contacts Nos 6 7 8 for power off on terminals Nos 4 5 b State of output contacts and the optical level switch for the electrode emerged above the surface c State of output contacts and the optical level switch for the immersed electrode 1 CZP 1 sensor 2 Conductive liquid 3 Tank 4 Sensor housing according to DT UC 90 WO A 02 item 8 2 1 5 Connection line 6 DPZ 2R converter 7 Level switch output Sz green lamp optical signalling Sc red lamp optical signalling Rd additional range resistor to set the range sensitivity of the converter Cd additional capacitor to set the switching time above the nominal one P output relay DPZ 2R om Ro Fig 5 Non inversion type maximum level signalling circuit key see Fig 4 a Circuit diagram position of output contacts Nos 6 7 8 for power off on terminals Nos 4 5 b State of output contacts and the optical level switch for the immersed electrode c State of output contacts and the optical level switch for the electrode emerged above the surface PTFE j CZP 1 Fig 6 Sample installation of CZP 1R1 4 sensor inside a pipe or a tank it is recommended to follow the gene
18. ions must be as low as possible so that in case of any short circuit the voltage that might occur on the accessible conductive components does not exceed the value of 10V for the short circuit current equal to double rated current of the fuse used in the circuit protected Caution Should any of the input circuits terminals Nos 9 10 11 1 2 3 be accessible to people and or animals this applying also to sensors connected to those terminals and or other components which conduct electricity 12V DC or 24V DC or 24V AC converters must be used and the circuits connected to the outputs terminals Nos 6 7 8 must be of safe voltage type e g 24V Where a higher voltage is to be used e g 230 V additional protective impedance must be installed e g protective differential switch For versions supplied with voltage higher than safe voltage e g 230V whole of the power must be supplied via protective differential switch In addition to the above conditions quick break fuses must be used in the power supply circuits connected directly or indirectly with the converters corresponding to the power of the appliances connected but in any case of the rating not exceeding In 8A such circuits must be equipped with an easily accessible explicitly marked and easily identifiable switch compliant to PN EN 60947 1 Install the switches in places free from risk of mechanical impact this applying mainly to terminals or use appropriate guards It is recommended to i
19. nstall the sensor in the upper see example in Fig 6 or side wall of the tank or on extension arms positioned vertically or obliquely down Horizontal and other mounting positions are allowed for fairly clean liquids Order sensors with extended insulation for heavily polluted liquids The sensor mounting hole should have an appropriate thread type e g G 1 4 for R1 4 M20x1 5 for MK20x1 5 undamaged without sharp edges chips etc Seal the pressure vessels sensor thread with thread teflon PTFE tape Cut the electrode to length before mounting the sensor The length of the non insulated electrode part should be 5 mm recommended gt 50mm Where an electrode gt 0 95m must be used extend it with additional EKD 1 electrodes supplied to order for lengths of approx 2 mand more and or strong liquid swirls the use of CZP 1w reinforced sensors is recommended For heavy exposure purposes and dry loose materials use heavy duty CZP 1cG sensor see category card CZP 1cG Gaps between the sensors and the distance from the tank walls depend on the sensor type its length and the condition of the liquid For lengths up to approx 0 45m for CZP 1 and up to approx 1m for CZP 1w and where no swirl in the liquid is present the gaps can be up to several centimetres Where heavy swirls occur and for longer sensors gaps of several tens of centimetres and more may be necessary A general principle the longer the electrode the further it is placed from the
20. ral principles illustrated in the figure also for installation of other sensor types 4 SPC 1K level switch parameters DPZ 2R converter CZP 1 sensor probe Power supply Un options 50Hz ee for CZP 1w version lt 100 C possible lt 250 C Moisturized materials 1H18N9T PTFE PE for w version 100 C x mm ysteresis rel to the 30 for CZP 1w type 8 mm switch thresh ime delay 7 sec t lt 1 Cd 5 e 10 Electrode lengths m L 0 15 0 45 0 95 1 0 2 0 for DPZ 2Rzw version ft ON lt 1 t OFF 5 sec Additional electrodes EKD 1 O4 in EKD 1w 8 L 1 m with ery low lt 7 V extending the sensor hreaded ends and a thread connector Insulating strength 2 5KV 4kV relay and Insulation strength 1 0 kV dry ransformer Protection grade IPO 7 erminal protection grade IP 55 IP67 if cap filled with silicone Overvoltage category Applied voltage at the sensor K 50 V AC DC Upon agreement the parameters can be changed to be made more stringent according to the user s requirements If used for caustic liquids e g acids provide type strength and temperature of liquid in order to select an appropriate material of the electrode and housing Converter sensitivity switching threshold range arithmetic mean of two resistance values for which the output relay is switched on and off resulting from the resistance value of the additional range resistor Rd and optionally the
21. rangement as per Fig 4 The additional range Rd resistor value determines the converter sensitivity i e determines the sensor circuit impedance value for which the relay output contacts are switched the sensor circuit impedance value is based on 1 a how deep the electrode is immersed in the liquid and on the liquid conductivity the additional range Rd resistor indicated under Pos 1 above is selected in such a way that the SPC 1 level switch operates effectively even for the liquid conductivity of one order of magnitude lower i e 20 US cm and for electrode immersion not more than 20 mm according to the requirements of technical conditions of the technical inspection DT UC 90 WO A 02 item 8 3 2 For Rd values indicated in column 4 and for the liquid conductivity values given in column 3 the switching of the relay output contacts occurs for the sensor electrode immersion not exceeding 2 mm Recommended values although actually the binding requirements are as per WT SPC 1 x Applicable for 1 a steam boilers subject to Technical Inspection kek Can be used only after individual tests at the user s facility On request the manufacturer can offer variable adjustment resistors of the following ratings 5kQ 10kQ 100kQ IMQ and other the resistors are connected to terminals as Rd or Rdr and enable selection of any converter sensitivity Where liquids are used which form conductive coatings on the insulator or insulation coatings on
22. ty liquids the manufacturer shall supply special converter types DPZ 2Rzpp resistant to very strong interference at very high sensitivity 7 Orders The following should be given in the order name type version and quantity of DPZ 2R converters size and type of sets in box housings values and quantities of Rd Rdr optionally adjustable see above and Cd if necessary as well as quantity type version thread type insulation length Gf of non standard type and lengths of individual CZP 1 sensors see Fig 3 and 4 and optionally quantity of additional electrodes Electrodes made of silver platinum or hastelloy are available to be used for various media Sensors for higher temperature and pressure values are also available DPZ 2R converters can be supplied in tight gt IP 55 insulating box type plastic enclosures protection class II with one ore more converters inside one enclosure including contactors and other elements according to the request of the ordering party Multi line block designation e g 2xDPZ 2R means 2 pieces of DPZ 2R in plastic IP 55 box enclosure with transparent cover DPZ 2R 2xDPZ 2R 4xDPZ 2R Table 3 Spacing of Number of lines Enclosure dimensions mounting holes 75x125x100 60 x 110 O22 e pieces of POD chokes 125x125x100 110 x 110 2xDPZ 2R 3 pieces of PGI 1 chokes 125x175x100 110 x 160 3xDPZ 2R 4 pieces of PG11 chokes yt Z Z 175x250x100 160 x 235 Ca CZP 1 R1 4 1m
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