5200 Service Manual - AMETEK Factory Automation
Contents
1. 3 Check A 4 amp A 6 D Constant Chatter l i If load relay contacts chatter continuously check defective control as in A 2 1 If relay now operates correctly check A 4 amp A 6 B C 1 and C 2 2 If relay still chatters with terminals 13 amp 14 jumpered together the load relay is defective or the capacitor across the load relay coil may be defective E Load Relay Will Not prep Out If relay will not drop out when liquid falls below lower electrode check the following points 1 Defective Control See A 2 2 Grounded Electrode Leads A ground in the lead wire to the upper or lower electrode will prevent the relay from dropping out on low liquid level If the distance from the holder to the control is relatively short the best way to check for ground is to connect replacement wires from the terminal strip to electrode holder outside of conduit and test for proper eat If load lal drops out properly itis safe to assume that a ground exists in the original wires to the electrode holder If control is located a considerable distance from the electrode holder check for ground as follows Disconnect power remove wires from terminals in electrode holder and allow them to stick up in the air to eliminate the possibility of contacting a grounded part Then turn on power If load relay pulls in a shortis indicated in the upper lead wire to ground between the control and the electrode holder If the load relay does no2. ata point where the liquid cannot make contact All installations should of course be checked to make sure that the proper electrode lengths are provided If stand pipes are used make sure pipe is vented above upper electrode setting B One Level Operation If control operates at one level only starts and stops at one electrode level check following 1 Electrode Wires If wires between control and electrodes are interchanged load relay will not operate over a range in level but from the lower electrode only To correct simply reverse electrode connections either at terminal strip or electrode holder 2 Holding Circuit If the holding circuit terminals 4 7 is not closing the load laa will operate from the upper electrode only If the holding circuit is not opening the relay will operate from the lower electrode only This holding circuit contact can be checked for continuity with an ohmmeter If defective and if contacts 2 5 8 are not being used for load connections contacts 5 8 can be used as a holding circuit contact Move the internal jumper from terminal 7 to terminal 8 and move the lower electrode connection from terminal 4 to terminal 5 C Intermittent Operation If the control occasionally short cycles or operates intermittently check the following 1 Continuously monitor input voltage for flictuations or voltage spikes 2 Check for physical vibration caused by contactors or magnetic starters mounted nearby
3. 0 ohms 50 000 feet Ordinary water with medium to highmineral 470 ohms 15 000 feet Strong electrolytes Plating solutions E Se di starch 1 000 0hm 19 000 feet nea eetos Ammonium hydroxide Dorax 22 000 ohms 50 000 feet Water with low mineral content soft not as z distilled or demineralized sugar syrup 1 800 ohms 11 000 feet fies processing applications Beer wine solutions long distance applications 3 900 ohms 5 000 feet Highly corrosive acid or caustic solutions where 68 000 ohms 50 000 feet AIA com syrup strong alcohol electrode current must be minimized to extend i electrode life Hydrochloric acid sulfuric acid 330 000 ohms _ 50 000 feet Alcohol solutions up to 70 etc 820 000 ohms 35 000 feet Deionized or distilled water 95 glycerine 90 10 000 ohms 12 000 feet Ordinary water with medium to high mineral hydrogen peroxide 95 ethyl alcohol granular content sewage water soluble oil and starch solids with high moisture content solutions 2 2megohms 12 000 feet Glacial acetic acid acetone granular solids with 22 000 ohms 900 feet Sugar syrup solutions most water with low some moisture content mineral content S oft water not distilled or 5 6 megohms 4 000 feet M E K Methyl ethyl ketone deionized water Use 5200 HF 2 Control 12 0 megohms 2 000 feet Anhydrous ammonia Distance shown in the tables above are based upon the use of two 18 gauge lead wires installed in 1 2 diameter conduit NOTE DI water glycols alc
4. 500 68 000 ohms 04 155100 1 800 ohms 04 138600 330 000 ohms 04 155200 3 900 ohms 04 138800 007 to 1 0 megohms 04 149400 10 000 ohms 04 138900 820 000 ohms 04 138400 22 000 ohms 04 139000 2 2 megohms 04 139100 5 6 megohms SERVICE INSTRUCTIONS B W Solid state controls are designed and built to require a minimum of service in the feld Each one is tested at the factory to insure positive operation and should not be altered or tampered with prior to installation If a control does not operate properly after it has been installed with the proper sensitivity resistor added the following information will be helpful in determining the probable cause Direct Operation In direct operation the load relay is energized when the liquid reaches the upper electrode or Unifbat reed switch level and electrode current is fbwing Be sure sensitivity resistor has been installed between terminals 14 and 15 and a good ground connected to terminal 13 Chassis Ground n Through Mounting Screw Load Contacts AC Line 230V 115V or 230V 50 or 60 Hz 115V SERIES 5200 Sensitivity Resistor Ground return to tank or electrode if required H1 TO PUMP STARTER VARIABLE RESISTANCE POTENTIOMETER OPTIONAL AT EXTRA COST ELECTRODE HOLDER PUMP STARTS PUMP STOPS TANK PUMP DOWN A Load Relay Will Not Pull In 1 Power Failure or No Voltage at AC Line Terminals Voltage at power in pu
5. 5200 HF2 High Sensitivity Controls These controls operate with 9 6 volts dc on the sensing circuit and in general the maximum lead length is determined by the resistance of the lead wires These controls will operate reliably with electrode lead lengths of several miles butit is important to select the correct R1 sensitivity resistor to assure positive operation over these extreme distances Refer to Table on page 1 for suggested maximum lead lengths If your application involves greater distances than those shown please contact factory GROUND CONNECTIONS In all installations using electrodes a good external ground connection and a dependable return circuit to the liquid are required In most instances grounding to a metal pipe leading to the tank is suitable but electrical conduit should not be used for this purpose If a good ground connection to the liquid is not available an additional ground or common electrode is required When used the ground or common electrode should extend slightly below the longest operating electrode In addition itis also desirable to ground the control chassis directly to the ground terminal or through a mounting screw If PVC well casings or drop pipes are used to contain the electrodes a ground or common electrode is required R1 SENSITIVITY RESISTORS Both the high sensitivity and the low sensitivity controls are nipped from the factory with a complete set of fked resistors or with a variable res
6. B W Controls LIQUID LEVEL TECHNOLOGY 5200 Series 5200 Solid State Rela AL US E67365 PRINCIPLE OF OPERATION B W 5200 Solid State Controls are offered in two basic types for use in a wide range of low and high sensitivity applications Both are designed to operate on either 115 or 230 volts AC at 50 60 hertz Both incorporate a low voltage sensing circuit Both are also capable of performing control functions directly from electrodes suspended in a well or tank the B W Unifbat level sensing system or various pilot devices such as pressure fbw and limit switches thermostats and pushbuttons etc In addition their operating characteristics are virtually unaffected by ambient temperatures ranging from 40 F to 180 F or by variations from 80 to 110 of their rated voltage Both controls are also furnished with a complete set of R1 fixed sensitivity resistors or a variable resistance potentiometer to permit adjustment of operation based on the resistance of the liquid or material to be controlled See tables below 5200 LF 1 Low Sensitivity Control The basic components of this control are a transformer a circuit board with voltage divider circuit a silicon controlled rectifer SCR and a load to provide isolated DP DT contacts The sensing circuit voltage is 8 0 volts ac 5200 HF 2 High Sensitivity Control This control is similar to the 5200 LF 1 but with two basic differences First a rectifer is used to convert t
7. ECK TRANSFORMER Range LV2 52 110206 With the ac line voltage Ua to terminals 10 amp 11 or 10 amp 12 as shown on Potentiometer Kits for 5200 HV Form 448 the following voltages should be read between the transformer wire Range HV3 52 120205 connections on back of the control 15 Range HV4 52 120206 Range HV5 52 120207 Piece to ange Herein enna n ae Circuit Board Low 52 110114 Black to Blue 230 volts Circuit Board High 52 120114 Red to White 3 6 volts Transformer 52 110106 Red to BrOWN eee 7 2 volts Load Relay 04 261900 Brown to White 3 6 volts Terminal Block Li 04 281900 Green to YellOW sussies 30 volts una Ocse Terminal Block Probe 04 281800 If these out put voltages are not present and in put voltages check the See Sensitivity Range table shown on page 2 transformer is defective and should be replaced AMETEK AUTOMATION amp PROCESS TECHNOLOGIES e Copyright 2007 by AMETEK Automation amp Process Technologies 1080 N Crooks Road Clawson MI 48017 Toll Free 800 635 0289 Phone 248 435 0700 Fax 248 435 8120 www ametekapt com 432 5200 M4R 5 07 Z152
8. ce is sensed across terminals 13 amp 14 and the signal to the SCR becomes positive or in phase turning the SCR on which in turn energizes the load relay to start the pump When load relay is energized the holding circuit contact 4 7 closes to hold in the mey aori the lower electrode and the liquid resistance until liquid level falls below the lower or pump stop electrode at which time the SCR turns off and de energizes the load relay to stop the pump Inverse Operation bate In inverse operation load relay is de energized when the level sensing circuit is completed In this mode of operation function of load relay is reversed When operating from electrodes for pump up operation and liquid is below lower electrode a positive or in phase signal turns the SCR on energizing the load relay to start the pump When liquid rises to touch the upper electrode a negative or out of phase Signal turns the SCR off de energizing the load relay and stopping the pump The holding circuit contact 1 7 closes keeping the load relay de energized until the liquid again falls below lower electrode 5200 LF1 Low Sensitivity Control 5200 HF2 High Sensitivity Control R1 Sensitivity Maximum Lead Application R1 Sensitivity Maximum Lead Application Resistor Wire Lengths Recommondations Resistor Wire Lengths Recommondations 270 ohms 15 000 feet All metallic circuits BAW Controls Unifbat 10 00
9. de Leads A ground in the lead wire to the upper or lower electrode will prevent the load relay from pulling in Section E 2 describes how to isolate the grounded wire when the relay is being used for direct operation This same method can be used when the control is being used for inverse operation but the functions must be reversed i e drop out interchanged with pull in In section E 2 bridge between terminals 14 amp 15 instead of 13 amp 14 4 Electrode Holder See Section E 3 5 Length of Lead Wires Excessive distance will not allow the 5200 LF 1 low sensitivity control to operate when the liquid drops below the lower electrode See Section E 4 G One Level Operation bat relay operates at one level only starts and stops at one electrode check ollowing 1 Electrode Wires See Section B 1 2 Holding Circuit If the holding circuit contacts 1 7 is not opening the load relay will operate from the lower electrode ony If holding circuit is not closing the relay will operate from the upper electrode only As in Section B 2 for direct operation If contact 1 7 is defective contacts 2 8 can be used as an alternate holding circuit contact H Intermittent Operation i he relay occasionally short cycles or operates intermittently check the ollowing 1 See Section C 1 and C 2 2 Check Section J 3 and J 5 Constant Chatter If load relay chatters continuously check as in Section F 2 If relay now o
10. he sensing circuit voltage from ac to 9 6 volts dc second a feld effect transistor FET is added to provide higher sensitivity This permits positive operation on liquids with very high resistance Since the voltage divider circuit compares the liquid resistance to the R1 sensitivity resistor on both 5200 LF1 and 5200 HF2 controls it is important that the R1 resistor selected be rated higher than the resistance of the liquid or other sensing circuit INSTALLATION amp SERVICE MANUAL Basic Specifications Dual Voltage Either 115 or 230 volts AC at 50 60 hertz Contacts Silver Cadmium Oxide ContactRatings 10 amperes at 120 or 240 volts AC or 28 volts DC mgs 1 4 hp at 120 volts AC and 1 3 hp at 240 volts AC Arrangement Double pole double throw load contacts plus single pole doublethrow holding circuit contacts 9 volt ampere 6 watt 40 F to 180 F AC 8 volts less than 30 milliamperes for 5200 L DC 9 6 volts less than 1 milliampere for 5200 H Power Required Operating Temp Low Energy Sensing Circuit Direct Operation In direct operation the load relay is energized when the level sensing circuit is completed When operating from electrodes for pump down operation and liquid is below lower electrode a high resistance is sensed across terminals 13 amp 14 and a negative or out of phase signal is fed to the SCR When liquid rises to touch the upper electrode a low resistan
11. istance potentiometer Variable resistance potentiometers are furnished in three different ranges according to the table which follows Sensitivity Ranges Relay Type R1 Resistor Direct Operation Inverse Operation 5200 LF1 Fixed R1 Up to 16 000 ohms Up to 26 000 ohms Resistor 5200 LV1_ Variable 100 to 700 ohms 200 to 1 200 ohms 5200 LV2 Variable 600 to 15 000 ohms 1 000 to 24 000 ohms 5200 HF2 Fixed R1 Up to 11 6 megohms Up to 12 0 megohms Resistor 5200 HV3 Variable 2 000 to 100 000 ohms 2 000 to 100 000 ohms 5200 HV4 Variable 007 to 1 0 megohms _ 007 to 1 0 megohms 5200 HV5 Variable 047 to 5 0 megohms 047 to 5 0 megohms To determine which fed sensitivity resistor to install please refer to the table which follows When operating from electrodes select a resistor having a sensitivity value greater than the specift resistance of the material to be controlled Any of the resistors can be used when operating from switch contacts but the smallest value is recommended Fixed resistance R1 resistors should be installed as shown on the wiring diagram furnished with the control Fixed Resistor Sensitivity 5200 LF1 Sensitivity Control 5200 HF2 High Sensitivity Control Part Number Nominal Resistance Part Number _ Nominal Resistance 04 154900 270 ohms 04 149400 10 000 ohms 04 155000 470 ohms 04 138400 22 000 ohms 04 138300 1 000 ohms 04 138
12. l in In this event a 5200 HF2 high sensitivity control should be used Inverse Operation In inverse operation the relay is energized when liquid falls below the lower electrode and current ceases to fbw Be sure sensitivity resistor has been installed between terminals 13 amp 14 and a ground connected to terminal 15 L Chassis Ground AC Line 230V 71 Through Mounting Screw i 115V or 230V 2 L_____ 115V a Fr H H s 50 or 60 Hz SERIES 5200 Load Contacts Q Q 2 i TO PUMP g GL STARTER VARIABLE RESISTANCE POTENTIOMETER OPTIONAL AT EXTRA COST Sensitivity Resistor Ground return to tank or electrode if required ELECTRODE HOLDER PUMP STOPS PUMP STARTS PUMP UP F Load Relay Will Not Pull In If relay will not pull in when liquid drops below lower electrode failure to operate is probably caused by one of the following conditions 1 Power Failure or No Voltage See Section A 1 under Direct Operation 2 Defective Controls To check the relay disconnect electrode and load connections from relay terminals Apply line voltage to the appropriate terminals 10 amp 11 or 10 amp 12 and short between terminals 14 amp 15 with an insulated jumper wire The load relay should drop out when the jumper is connected and pull in when the jumper is removed Failure to do so indicates a defective control 3 Grounded Electro
13. ng is low the circuit board is defective If the voltage reading is high 39 to 44 volts dc the load relay has an open coil Inverse Operation Test the control as in F 2 with ister removed If load relay does not pull in check as above for 22 to 26 volts dc If voltage is low circuit board is defective If voltage is high 39 to 44 volts dc load relay has an open coil Replace the circuit board or the load relay as required See parts list for details If a competent technician is not available the control should be returned to factory for repair or replacement 5200 RELAY CHASSIS DIMENSIONS I F i All B W controls are tested at the factory prior to shipment to insure proper Replacement Fante ior 2200 Salic Sieie Conroe Diab They should be handled with care during installation to avoid breaking Description Part Number electrical connections If the control does not operate properly after ithas been Resistor Set Low 52 110105 installed and service instructions indicate a defect repair should be attempted Resistor Set High 52 120105 only by an experienced electronic technician as follows P otentiometer Kits for 5200 LV Range LV1 52 110205 CH
14. ohols and granular solids may require the 2 2 5 6 or 12 0 megohms R1 resistor depending upon their purity or moisture content INSTALLATION INSTRUCTIONS These instructions relate primarily to the B W electrode system of liquid level sensing Call 1 800 635 0289 to request the B W Catalog 266 for complete speciftations wiring and electrode equipment etc ELECTRODE LEAD WIRES Shielded cable is not required Generally the size of the wire used is passed upon the physical strength required to meet given installation condition Size 14 to 18 gauge wire is generally strong enough for private buried or overhead wiring although size 26 gauge wire is adequate for positive relay operation In some long distance applications communication cable or telephone circuits may be used In all cases however control circuit wires must have good ee and splices or connections must be watertight and insulated from ground Special Note In order to prevent feed back which can cause faulty operation electrode lead wires should not be run in the same conduit with power or load carrying circuits ELECTRODE LEAD WIRE LENGTH 5200 LF1 Low Sensitivity Control These controls operate with 8 volts ac on the sensing circuit and in general the maximum lead length is determined by the capacitance of the lead wires and the value of the R1 sensitivity resistor Refer to Table on page 1 for suggested maximum lead lengths
15. perates correctly check Sections J 3 amp J 5 G and H If load relay still chatters with terminals 14 amp 15 disconnected the relay is defective or there is a defective capacitor in the circuit board J Load Relay Will Not Drop Out me relay will not drop out when the liquid touches upper electrode check the ollowing 1 Defective Control See F 2 2 Poor Ground Connections A good Sel ballet ground connection should be made to terminal 15 to complete the circuit back to terminal 14 as indicated in Section A 3 3 Broken Wires A broken or loose wire from the control to upper electrode or ground common electrode will prevent load relay from dropping out Check as in Section A 4 but pull in should be replaced with drop out in the description 4 Sensitivity Resistor Too Low If the sensitivity is too low the load relay will not drop out or will buzz and chatter See A 5 but pull in should be replaced by drop out 5 Fouled Electrodes w Accumulated deposits on the electrodes will insulate them and prevent the load relay from dropping out See Section A 6 6 Electrodes Too Short See Section A 7 CONTROL REPAIRS TEST CIRCUIT BOARD AND LOAD RELAY Direct Operation Test the control as in A 2 with jumper between terminals 13 amp 14 If load relay does not pull in check on circuit board between two black wires leading from load relay for a reading of 22 to 26 volts dc If the voltage readi
16. t pull in short the relay with a piece of insulated wire by bridging between relay terminals 13 amp 14 The load relay should pull in when this connection is broken If the relay does not drop out a short to ground is indicated in the lower electrode lead between the control and electrode holder If any of these conditions exist disconnect the power and replace the grounded wires 3 Electrode Holder Excessive dirt or moisture over the insulation at the electrode holder or the electrodes can cause faulty operation The interior of the electrode holder and its underside should be kept clean and dry Conduit connection should be made so that no condensation can enter the holder The underside of vertically mounted holders should never come in contact with the liquid Insulated rod electrodes should be used with horizontally mounted holders Electrodes should be kept clean and free of dirt or grease A periodic check should be made to make sure that they do not become fouled with fbating debris or insulating deposits 4 Length of Electrode Lead Wire On installations with excessive distance over 1 000 feet between a 5200 LF1 low sensitivity control and the tank capacitance in the lead wires from the control to the electrodes may affect normal operation If wired for direct operation capacitance would cause the load relay to hold in when the liquid leaves the lower electrode If wired for inverse operation the load relay would fail to pul
17. t terminals should be 115 volts ac between terminals 10 amp 11 or 230 volts ac between terminals 10 amp 12 2 Defective Control To check control disconnect electrode and load connections from control terminals Apply line voltage to the appropriate terminals 10 11 or 10 12 and touch terminals 13 and 14 with an insulated jumper wire Load relay should pull in when the jumper is connected and drop out when the jumper is removed Failure to do so indicates a defective control 3 Poor Ground Connection Controls will not function unless a good dependable ground connection is made to terminal 13 If a load relay does not pull in when liquid contacts the upper electrode check ground connection to be sure it complies with installation instructions 4 Broken Wires A broken or loose wire from the control to the upper electrode or the ground common electrode will prevent load relay from pulling in Broken wires can be checked by shorting the upper electrode to ground or to the common electrode if used at the electrode holder If relay fails to pull in one or both of the electrode leads is open The individual leads can be checked by running temporary wires from the control to the electrode holder outside of conduit If the load relay now pulls in when shorting electrodes as noted above the break is between the control and electrode holder If load relay pulls in when the leads are shorted with a jumper at holder but not at electrode
18. tips the break is in the electrode suspension wire 5 Sensitivity Resistor Too Low If the sensitivity resistor value is too low for the resistance or conductivity of the iu to be controlled the load relay will not pull in or it will buzz and chatter before pulling in In either case the sensitivity resistor should be replaced with a higher value resistor see table page 2 If in doubt about R1 resistor selection furnish factory with details on liquid or send sample of liquid for testing 6 Fouled Electrodes Accumulation of dirt oil grease or other deposits on the electrodes may insulate them and prevent load relay from pulling in If this occurs the electrodes should be inspected and cleaned at regular intervals as required to eliminate the difftulty If unusual quantities of oil grease or sludge are encountered the electrodes can be mounted inside a pipe that is fushed with clean water A 4 pipe should be used with the bottom located below the lowest expected water level and vent holes provided atthe top so that the level inside and outside the pipe will be the same A small fbw of water entering the top of the pipe will cause an outward fbw of water from the bottom of the pipe and prevent undesirable material from entering Thus the electrodes have a clear surface on which to operate and will stay clean 7 Electrodes Too Short Itis possible for an installation to be completed in which the upper electrode is suspended
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