AMETEK 5200 Solid State Relay User Manual
INSTALLATION & SERVICE MANUAL
5200 Solid State Relays
Dual Voltage
Contacts
Contact Ratings
Arrangement
Power Required
Operating Temp.
Low Energy
Sensing Circuit
5200 Series
Basic Specifi cations
Either 115 or 230 volts AC at 50/60 hertz
Silver Cadmium Oxide
10 amperes at 120 or 240 volts AC or 28 volts DC,
1/4 hp at 120 volts AC. and 1/3 hp at 240 volts AC
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
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 Unifl oat level sensing
system, or various pilot devices such as pressure, fl ow 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 fi xed 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-LF1 Low Sensitivity Control
The basic components of this control are a transformer, a circuit board with
voltage divider circuit, a silicon controlled rectifi er (SCR), and a load to provide
isolated DPDT contacts. The sensing circuit voltage is 8.0 volts ac.
5200-HF2 High Sensitivity Control
This control is similar to the 5200-LF1, but with two basic differences: First, a
rectifi er is used to convert the sensing circuit voltage from ac to 9.6 volts dc;
second, a fi eld 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.
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 & 14, and a negative, or out-of-phase, signal is fed to the
SCR.
When liquid rises to touch the upper electrode, a low resistance is sensed
across terminals 13 & 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 relay through 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
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
R1 Sensitivity
Resistor
270 ohms 15,000 feet All metallic circuits, B/W Controls Unifl oat
470 ohms 15,000 feet Strong electrolytes: Plating solutions.
1,000 ohms 15,000 feet Weak eletrolytes: Ammonium hydroxide, borax,
1,800 ohms 11,000 feet Most food processing applications: Beer wine,
3,900 ohms 5,000 feet Highly corrosive acid or caustic solutions where
10,000 ohms 2,000 feet Ordinary water with medium to high mineral
22,000 ohms 900 feet Sugar syrup solutions, most water with low
Maximum Lead
Wire Lengths*
*Distance shown in the tables above are based upon the use of
two 18-gauge lead wires installed in 1/2” diameter conduit.
Application
Recommondations
acetic acid
fruit juices,milk buttermilk
electrode current must be minimized to extend
electrode life: Hydrochloric acid, sulfuric acid,
etc
content, sewage, water soluble oil and starch
solutions.
mineral content. (Soft water-not distilled or
deionized water. Use 5200-HF2 Control)
5200-HF2 High Sensitivity Control
R1 Sensitivity
Resistor
10,000 ohms 50,000 feet Ordinary water with medium to highmineral
22,000 ohms 50,000 feet Water with low mineral content (soft - not
68,000 ohms 50,000 feet Steam condensate, corn syrup, strong alcohol
330,000 ohms 50,000 feet Alcohol solutions up to 70%
820,000 ohms 35,000 feet Deionized or distilled water, 95% glycerine, 90%
2.2 megohms 12,000 feet Glacial acetic acid, acetone, granular solids with
5.6 megohms 4,000 feet M.E.K. (Methyl ethyl ketone)
12.0 megohms 2,000 feet Anhydrous ammonia
NOTE: DI water, glycols, alcohols and granular solids may require the 2.2, 5.6
or 12.0 megohms R1 resistor depending upon their purity or moisture content.
Maximum Lead
Wire Lengths*
Application
Recommondations
content, sewage, water soluble oil and starch
solutions, long distance applications
distilled or demineralized), sugar syrup
solutions, long distance applications.
solutions up to 50%
hydrogen peroxide, 95% ethyl alcohol, granular
solids with high moisture content
some 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 (Z66) for complete
specifi cations, 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
insulation, 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.
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, but it 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, it is also desirable to ground the control chassis directly to the ground
terminal or through a mounting screw.
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 04-138500 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 fi eld. 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 Unifl oat reed switch level, and electrode current is fl owing.
Be sure sensitivity resistor has been installed between terminals 14 and 15,
and a good ground connected to terminal 13.
!#,INE
6OR6
OR(Z
'ROUNDRETURNTOTANK
ORELECTRODEIFREQUIRED
3ENSITIVITY
2ESISTOR
6
6
3%2)%3
2%,!9
2
4!.+
,OAD
#ONTACTS
%,%#42/$%
(/,$%2
05-034!243
05-034/03
#HASSIS'ROUND
4HROUGH-OUNTING3CREW
4/05-0
34!24%2
6!2)!",%
2%3)34!.#%
0/4%.4)/-%4%2
/04)/.!,!4
%842!#/34
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 shipped from
the factory with a complete set of fi xed resistors or with a variable resistance
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
5200-LV1
5200-LV2
5200-HF2
5200-HV3
5200-HV4
5200-HV5
Fixed R1
Resistor
Variable
Variable
Fixed R1
Resistor
Variable
Variable
Variable
Up to 16,000 ohms Up to 26,000 ohms
100 to 700 ohms 200 to 1,200 ohms
600 to 15,000 ohms 1,000 to 24,000 ohms
Up to 11.6 megohms Up to 12.0 megohms
2,000 to 100,000 ohms 2,000 to 100,000 ohms
.007 to 1.0 megohms .007 to 1.0 megohms
.047 to 5.0 megohms .047 to 5.0 megohms
To determine which fi xed 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 specifi c 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.
2
PUMP DOWN
A - Load Relay Will Not Pull In
1. Power Failure or No Voltage at AC Line Terminals
Voltage at power in-put terminals should be 115 volts ac between terminals 10
& 11 or 230 volts ac between terminals 10 & 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 tips, the
break is in the electrode suspension wire.
Loading...