PHOTOSWITCH Liquid Level and Resistance Sensing Control Bulletin 13DJ3-3000

Transcription

1 Liquid Level and Resistance Sensing Control Bulletin 3DJ Product Data Description Features The Photoswitch Bulletin is a high sensitivity Liquid Level Control designed to detect the level of conductive liquids or solids with a moisture content as low as 5%. UL Recognized and CSA Approved Very high sensitivity up to 60 megohms cm liquid resistivity Compact, all solid state, plug-in, modular design for reliability with flexibility DPDT EM relay and VDC solid state outputs. Optional solid state logic outputs Low probe voltage isolated from line voltage Fast response time Wide selection of probe assemblies All molded parts of rugged, impact resistant NORYL Heavy-duty easy to wire terminals High voltage connections isolated from low voltage Ambient temperature range: -0 F to 35 F (-0 C to+57 C) NORYL is a registered trademark of the General Electric Company.

2 General The Bulletin Conductive Liquid Level Control is designed to provide a reliable level detection of conductive liquids or solids. No moving parts or floats are required. Metal probe rods are placed in the conductive liquid at the desired levels. The liquid or solid conductive material completes the circuit between the probe rod or rods to the metal material container. If the container is non-conductive (fiberglass, cement, etc.), an additional probe rod is used as a grounding probe to complete the electrical circuit. Completion of the circuit will cause the output relay to operate. The relay contacts may be used for pump, valve, or motor control; audible and/or visual level indication. The controls will operate over a resistivity range of 0 to 60 MegOhms-cm. This permits the sensing of liquids or solids with very low conductivity such as antibiotics, refrigerants, or sand with a moisture content as low as 5%. In addition to high sensitivity, the control has a fast response time and can be wired for electronic control latching on certain applications, allowing the use of both sets of relay contacts for external loads. A solid state output signal can be obtained from the control simultaneously with a relay output. This signal can be used for electronic counting, data logging, or feeding information to a computer. The control has protection against false operation due to line voltage transients, line voltage dropouts of / second or less, or during initial power up. These features allow the Control to be used in solving the more difficult industrial level applications. Resistance Sensing Control Photoswitch Bulletin 3DJ3 is also designed to be used as a resistance sensing control. In this application the control operates as an electronic switch which converts the minute current flow through delicate mechanisms or extremely light contacts into a switching output capable of handling relatively heavy electrical loads. The maximum sensitivity of the control when used for resistance sensing is 5 megohms.

3 Figure : Probes for Level Controls Series 6, 63, 6 Type 6LF probe fitting with Type 6CR probe rod and tip Type 6LJ probe fitting with Type 6CR probe rods and tips Type 63GH and 63GH sanitary probe fitting and rod assemblies Type 6BD probe fitting with Type 6CR probe rod and tip Type 6LF probe fitting with Type 6MR suspension wire and tip Probe Assemblies A selection of probe assemblies is available for a wide variety of applications. The probe assembly consists of a probe fitting threaded for convenient installation into a tank, vat, or other container; a stainless steel probe rod or insulated suspension wire which may be cut to the desired length for the particular installation; and a probe tip designed to provide the required surface area at a point of contact with the liquid. Figure shows typical probe assemblies. Series 6 probe fittings are ceramic insulated with stainless steel trim which may be used either alone or in one of a variety of metal enclosures. Single and double probe fittings are available. Series 63 sanitary probe fittings are available for dairy and other food processing installations. Sanitary probes do not require probe tips for satisfactory operation. Series 6 probe tip assemblies are combinations of a probe rod or suspension wire of the desired length with a suitable probe tip and are used with all Series 6 probe fittings.

4 Table : Level and Resistance Control BULLETIN NUMBER CONTROL BASE OUTPUT VOLTAGE SUPPLY OUTPUT CHARACTERISTICS TYPE RATING LEAKAGE 3DJ B 0VAC 50/60Hz 60-60B 0VAC 50/60Hz supplied with control base DPDT EM Relay 8-65 SPNO Triac AC 8-65 SPNO FET AC/DC 63-6 Voltage DC Output 63-5 NPN Open Collector 5A, 0VAC.5A, 0VAC A, 0VDC A, 65VAC 0mA min. 30mA, 0V AC/DC 30mA, VDC 50mA, VDC ma 0μA ma RESPONSE TIME Refer to Table 7 RESISTIVITY Refer to Table 6 Specifications Power Consumption: 3 watts (includes control base) Resistivity Range: Typical liquid resistivity 0-60 MegOhms centimeter (See Table 5) Resistance Sensing Sensitivity: 0-5 MegOhms in six ranges. (See Table 6, Consult factory for higher ranges.) Maximum Probe Voltage:.5 VAC (Ranges,, & 3), 9 VAC (Ranges, 5, & 6) (See Table 6) Maximum Probe Current: 65 ma to.00 ma. (See Table 6) Solid State Output Signal: VDC open circuit limited to 30mA short circuit. Terminals #5 and # on Control Base. Speed of Response:.003 sec. to.0 sec. (See Table 7) Permissible Lead Length: Up to,000 (609.6m) (See Table 8) Use #6 AWG wire minimum Ambient Temperature: - 0 F to 35 F (-0 C to57 C) 3

5 Table : Probe Fittings BULLETIN NUMBER 6BD LF LF- 000M 6LJ- 000 DESCRIPTION Probe fitting with rubber cap Probe fitting in cast enclosure Two probe fittings in cast enclosure RODS OR WIRES USED HOUSING MATERIAL FITTING PIPE THREAD None / Bronze 36 Stainless Steel Bronze MAXIMUM TEMPERATURE 300 F 9 C MAXIMUM PRESSURE PSI 50 (,7 kpa) 00 (,378 kpa) 50 (,7 kpa) 6LJ- 000M 36 Stainless Steel 00 (,378 kpa) 63GH- 000 Special sanitary Fits / LAMD 3H nut probe with 3 (.9m) for #5 Union Ferrule 63GH- 000 probe rod(s) supplied with 0 (3m) Fits LAMD 3H nut for None 63GJ- 000 cable and separable #5 Union Ferrule 63GJ- 000 connector F 00 C Table 3: Probe Rod Assemblies BULLETIN NUMBER 6CR CR- 00 6CR- 00 6CR CR- 00 6CR CR- 006 DESCRIPTION 36 Stainless Steel Probe Tip and / dia. x (.3m) Probe Rod 36 Stainless Steel Probe Tip and / dia. x (.6m) Probe Rod 36 Stainless Steel Probe Tip and / dia. x 36 (.9m) Probe Rod 36 Stainless Steel Probe Tip and / dia. x 8 (.m) Probe Rod 36 Stainless Steel Probe Tip and / dia. x 7 (.83m) Probe Rod 36 Stainless Steel Probe Tip and / dia. x 96 (.m) Probe Rod 36 Stainless Steel Probe Tip and / dia. x 0 (3m) Probe Rod Table : Spare Parts PART NUMBER DESCRIPTION APPLICATION 3-70 Rubber Cap For 6BD - 9- For 63GH -- 63GJ Connector and 0 (3m) CableAssembly - 50 For 63GH -- 63GJ 3- / diameter Teflon Spacer Separates double probes when the long probe exceeds 30 (76.cm) /--0 UNC Hex Nut Used with 6CR probe assemblies Insulation Suspension Wire Used when the required probe length exceeds 0 (3m) SS 5/8 diameter Suspension Wire Probe Tip Used when the required probe length exceeds 0 (3m) SS Adaptor Connects suspension wire to 6 Series probes SS 9/6 diameter Probe Tip Required on all probe rods for rated sensitivity Resistor Package For 3DJ

6 Figure 6BD Model 000 also used in 6LF- 6LJ all models NO RUBBER CAP / NPT Suspension wire adaptor and probe tip assembly SUSPENSION WIRE ADAPTOR NO PART NO PROBE ROD *PART NO. 3-- SUSPENSION WIRE NO ORDER SEPARATELY AND SPECIFY REQUIRED LENGTH PROBE TIP NO PROBE TIP ASSEMBLY NO *AVAILABLE AS OPTIONAL EXTRA WITH DOUBLE PROBE ASSEMBLIES, WHEN EITHER ROD EXCEEDS 30 INCHES IN LENGTH. See Table for further description. 5

7 Table 5: Typical Control Ranges and Probe Materials TYPICAL LIQUID CONCENTRATION (% by weight) RESISTIVITY (ohms cm) CONTROL SUITABLE PROBE MATERIAL Acetate Acid ,300 HC Ammonia 6.--5,000--,000 SS Ammonium Chloride HB, HC Ammonium Iodide SS Ammonium Nitrate SS Ammonium Sulfate HC Antibiotics 00,000-- MΩ 5 SS Barium Chloride SS Barium Nitrate SS Beer 00--,000 or SS Butyric Acid --0,000--,000 SS Cadium Bromide SS Cadium Chloride SS Cadium Iodide SS Cadium Nitrate SS Cadium Sulfate SS Calcium Chloride SS Calcium Nitrate SS Copper Chloride HB, HC Cupric Nitrate SS Cupric Sulfate SS Distilled Water 0, ,000 3 SS Formic Acid SS Hydrobromic Acid HB Hydrochloric Acid HB Hydrofluoric Acid M, HC Hydroiodic Acid 5 8 SS Lead Nitrate SS Lithium Carbonate SS Lithium Chloride SS Lithium Hydroxide SS Lithium Iodide SS Lithium Sulfate 5 5 SS Magnesium Chloride M Magnesium Nitrate SS Magnesium Sulfate SS Mercuric Bromide , ,000 3 SS Milk 00--,000 or SS Nitric Acid SS Oxalic Acid SS Phosphoric Acid HC Potassium Acetate SS Potassium Bromide SS Potassium Carbonate SS Potassium Chloride SS Potassium Cyanide SS Potassium Fluoride SS Potassium Hydroxide M Potassium Iodide SS Potassium Nitrate SS Potassium Oxalate 0 SS Potassium Sulfate 0 M 6

8 Table 5: Typical Control Ranges and Probe Materials (continued) TYPICAL LIQUID CONCENTRATION (% by weight) RESISTIVITY (ohms cm) CONTROL SUITABLE PROBE MATERIAL Potassium Sulfide SS Propionic Acid ,00 M Refrigerants MΩ--0MΩ 5or6 SS Silver Nitrate SS Sodium Acetate SS Sodium Carbonate SS Sodium Chloride SS Sodium Hydroxide M Sodium Iodide SS Sodium Nitrate SS Sodium Sulfate SS Sodium Sulfide SS Strontium Chloride SS Strontium Nitrate SS Sulfuric Acid HC Synthetic Latex MΩ--0MΩ 6 SS Tapwater,000--0,000 3 SS Zinc Chloride M Zinc Sulfate SS Measured at normal room temperature Suitable Probe Materials SS = 36 Stainless Steel (standard) M = Monel HB = Hastelloy B HC = Hastelloy C Table 6: Level and Resistance Sensing Ranges LIQUID RESISTIVITY ohms/cm RESISTANCE SENSING RESISTOR Ω -- Orange -- Orange -- Brown 330Ω , ,500Ω -- Red -- Violet -- Red,700Ω 3 6, ,000, ,000Ω -- Red -- Violet -- Orange 7,000Ω 60, MΩ 5, ,000Ω -- Red -- Violet -- Yellow 70,000Ω 5.6MΩ -- 6MΩ 50, MΩ -- Red -- Violet -- Green.7MΩ 6 6MΩ -- 60MΩ MΩ -- Red -- Violet -- Blue 7MΩ MAXIMUM VOLTS MAXIMUM CURRENT TYPICAL SOLUTIONS.5 VAC 65 ma Acids Bases Salts.5 VAC 8.33 ma Beer Milk Water.5 VAC.83 ma Water Alcohols Distilled Water 9 VDC. ma Alcohols Ammonia Distilled Water 9 VDC.0 ma Antibiotics Refrigerants 9 VDC.00 ma Refrigerants Synthetic Latex Note: All range resistors are / W ± 0% except Range, which is W. 7

9 Table 7: Speed of Response (seconds) SOLID STATE OUTPUT RELAY OUTPUT ON OFF ON OFF Ordering Instructions. Select 3DJ Select Control Base BULLETIN NUMBER VOLTAGE SUPPLY DESCRIPTION B 0 VAC Open Type 60-60B 50/60 Hz NEMA Enclosure 60-60B 30 VAC Open Type 60-6B 50/60 Hz NEMA Enclosure For NEMA 3,,, and 3; order open type base and enclosure. 3. Select Probe Fitting BULLETIN NUMBER 6BD LF LF- 000M 6LJ LJ- 000M DESCRIPTION Probe fitting with rubber cap Probe fitting in cast enclosure Two probe fittings in cast enclosure RODS OR WIRES USED Note: 6 Series probe fittings require suitable Series 6 probe tips and probe rod or suspension wires shown below. 63GH- 000 Special sanitary probe 63GH- 000 with 3 (.9m) probe rod(s) supplied with 63GJ (3m) cable and 63GJ- 000 separable connector 8

10 . Select Probe Rod Assemblies for 6 Series Probe Fittings BULLETIN NUMBER 6CR CR- 00 6CR- 00 6CR CR- 00 6CR CR- 006 DESCRIPTION Probe Tip and / dia. x (.3m) Probe Rod Probe Tip and / dia. x (.6m) Probe Rod Probe Tip and / dia. x 36 (.9m) Probe Rod Probe Tip and / dia. x 8 (.m) Probe Rod Probe Tip and / dia. x 7 (.83m) Probe Rod Probe Tip and / dia. x 96 (.m) Probe Rod Probe Tip and / dia. x 0 (3m) Probe Rod Installation The control point for liquid level is the point at which the liquid makes or breaks contact with the probe tip and is determined by the length of the probe rod. Rods may be ordered to size, or may be supplied longer than required and cut to the desired length. One end of the rod is threaded for connection to the probe fitting. The unthreaded (cut) end should be inserted in the probe tip and held by means of a set screw. For deep well and other long probe applications over 0 (3m), suspension wires and tips should be installed. Standard probe tip 6-388, is used with all probe rods. Special probe tip 6-38 with insulating sleeve, is used with suspension wire. The probe rod or suspension wire adaptor is connected to the probe fitting as follows: 6 Series fittings have a / -0 female thread to receive the / -0 male thread of the probe rod or suspension wire adaptor. When the long probe of any multiple probe assembly is over 30 (.76m), a Teflon insulating spacer 3 -, is fitted over the short probe rod immediately above the probe tip to prevent the rods from touching. For suspension wire assemblies, an insulating sleeve fits over the probe tip to prevent it from touching other surfaces. Series 63 sanitary probes for dairy and food industry applications are made for special sanitary fittings. The probe insulator is made to fit a #5 union ferrule and to be secured with a #3H union nut. The ferrule and nut are supplied by the customer and are soldered, brazed, or otherwise secured before insertion of the probe assembly. Probes 63GH and 63GH fit -/ ferrule, while probes 63GJ and 63GJ fit a ferrule. All Series 63 probe rods are 3 (.9m) long and are to be cut to length on the job. Mounting 3DJ3 controls may be mounted in any position on a sturdy wall, partition, panel board, bracket, or similar support. While the NEMA enclosure is being mounted, the control base should be stored in a safe place to avoid moisture and mechanical damage. The enclosure mounting hole dimensions are shown on page and sheet metal, wood or machine screws, bolts, or similar fasteners may be used. When the housing has been securely fastened, connect the cables or conduits to the housing in the knock out holes provided and replace the control base. 9

11 The wiring between the control and the probes should not exceed the lengths listed below. Table 8: Maximum Recommended Cable Length CABLE LENGTH 000 (609.6m) 000 (30.8m) (5.m) 000 (609.6m) (609.6m) 6 50 (5.7m) Resistor Selection Wiring When the resistivity of the liquid is known, convert to ohms cm and select the range resistor that corresponds to the resistivity range in Table 5. When the resistivity of the liquid is not known, immerse the high level probe tip /6 (.5mm) into the liquid. For operation with the relay energized with the probe immersed, connect the Range resistor (330 ohms) to Terminals and. The relay should energize. If it does not, use successively higher range resistors until the relay energizes. If relay action is sluggish, use the next higher range resistor. For operation with the relay de-energized with the probe immersed, connect the Range resistor (330 ohms) to Terminals and 3. The relay should de-energize. If it does not, use successively higher range resistors until the relay de-energizes. If relay action is sluggish, use the next higher range resistor. Note: For resistance sensing applications, use the values of resistance sensing sensitivity listed in Table 6 in place of probe circuit resistivity for selection of the proper range resistor. Note: Wiring for Ranges --3 differs from Ranges Follow wiring instructions in Wiring Diagrams in Figures 6-. All external wiring should conform to the National Electric Code and applicable local codes. See wiring diagrams for external connections. Wire no smaller than 6 AWG is recommended. WARNING: Do NOT run probe or reset leads in same conduit with power lines or high current carrying conductors. Since the 3DJ3 control operates with liquids having high electrical resistance, the insulation resistance of the wiring connecting the control to the probe must be extremely high. It is important, therefore, to use plastic insulated wire to insure that the insulation will not absorb moisture or crack and permit leakage paths to develop. Wires insulated with paper, cotton, asbestos, etc. must not be used. Series 63 sanitary probes are furnished with a molded separable connector and 0 (3m) cable assembly. 0

12 Outline and Mounting Dimensions Unless otherwise indicated, dimensions shown are in inches. Those in parentheses are in millimeters. NEMA # * (00).875 (.) * NEMA 3,, 5, & 3 #6-090 (0.6).375 (9.5) 5.5 (33.).88 (.8) (50.8) 7.5 (8.) 8.5 (09.5) 8.75 (.) * * 9.5 (.3).8 (0.6).875 (3.8) (50.8).375 (9.5).688 (7.5).3 (7.9) HOLE () *.875 DIA. (.) 8 K.0. S TOTAL.375 (9.5) TYP..88 (30.) * (98.) Figure 3 Figure.063 (7) 6.5 (58.7).65 (5.9).875 (3.8) OPEN TYPE.03 (.8).53 (3.5) EITHER MAY BE USED FOR THIRD MOUNTING HOLE.375 (60.3).375 (9.5) 5.5 (33.3).78 (.) #8 SCREW TERMINALS (6).5.5 (3.7).5 (63.) MTG.HOLES.85 DIA. (.5) 3.65 (9.).5 (57.) Figure (79.) WITH INSTALLED PLUG-IN MODULE

13 TYPICAL SERIES 3DJ3 WIRING DIAGRAMS LOW LEVEL ALARM LINE VOLTAGE LOW LEVEL ALARM SELF-LATCHING WITH PUSH BUTTON RESET LINE VOLTAGE ALARM INC IN0 IC L NC N0 C L ALARM INC IN0 IC L NC N0 C L 3DJ3-- MODEL 3000 PLUG-IN CONTROL MODULE 3DJ3-- MODEL 3000 PLUG-IN CONTROL MODULE RESISTOR RESISTOR N.C. RESET SWITCH Single probe low level alarm. The relay is de-energized with probe immersed and energized with probe out of liquid. Connections are shown for operation on ranges, & 3. For operation on ranges, 5 & 6, connect range resistor to terminal instead of terminal 3. Single probe low level alarm with electronic latching & push button reset. The relay is de-energized with probe immersed and energized with probe out of liquid. Connections are shown for ranges, & 3. For operation on ranges, 5 & 6 connect range resistor to terminal instead of terminal 3. Figure 6 Tank must be grounded Figure 7 Tank must be grounded HIGH LEVEL ALARM LINE VOLTAGE HIGH LEVEL ALARM SELF-LATCHING WITH PUSH BUTTON RESET LINE VOLTAGE ALARM INC IN0 IC L NC N0 C L ALARM INC IN0 IC L NC N0 C L 3DJ3-- MODEL 3000 PLUG-IN CONTROL MODULE 3DJ3-- MODEL 3000 PLUG-IN CONTROL MODULE RESISTOR SOLID STATE OUTPUT V MIN RESISTOR N.C. RESET SWITCH Single probe high level alarm. The relay is de-energized with probe immersed and energized with probe out of liquid. Connections are shown for operation on ranges, & 3. For operation on ranges, 5 & 6, connect range resistor to terminal instead of terminal 3. Single probe high level alarm with electronic latching & push button reset. The relay is de-energized with probe immersed and energized with probe out of liquid. Connections are shown for ranges, & 3. For operation on ranges, 5 & 6 connect range resistor to terminal instead of terminal 3. Figure 8 Tank must be grounded Figure 9 Tank must be grounded

14 TYPICAL SERIES 3DJ3 WIRING DIAGRAMS (continued) PUMP UP CONSTANT LEVEL CONTROL LINE VOLTAGE PUMP DOWN CONSTANT LEVEL CONTROL LINE VOLTAGE PUMP INC IN0 IC L NC N0 C L PUMP INC IN0 IC L NC N0 C L 3DJ3-- MODEL 3000 PLUG-IN CONTROL MODULE 3DJ3-- MODEL 3000 PLUG-IN CONTROL MODULE 8 8 RESISTOR SOLID STATE OUTPUT V MIN RESISTOR A double probe installation, used for pump-up constant level control. The relay is de-energized when the upper probe is immersed and does not energize until the liquid drops below the lower probe. Connections are shown for ranges, & 3. For operation on ranges, 5 & 6 connect range resistor to terminal instead of terminal 3. Figure 0 Tank must be grounded A double probe installation, used for pump-down constant level control. The relay is energized when the upper probe is immersed and de-energized when the liquid drops below the lower probe. Connections are shown for ranges, & 3. For operation on ranges, 5 & 6 connect ground to terminal instead of terminal 3. Figure For insulated tanks, a grounded third probe must be added as shown. If an additional wire is run between the control ground and the third probe, it should be grounded at the control. PUMP DOWN CONSTANT LEVEL CONTROL LINE VOLTAGE PUMP INC IN0 IC L NC N0 C L 3DJ3-- MODEL 3000 PLUG-IN CONTROL MODULE RESISTOR A double probe installation, used for pump-down constant level control. The relay is energized when the upper probe is immersed and de-energized when the liquid drops below the lower probe. Connections are shown for ranges, & 3. For operation on ranges, 5 & 6 connect range resistor to terminal instead of terminal 3. Figure A For insulated tanks, a grounded third probe must be added as shown. If an additional wire is run between the control ground and the third probe, it should be grounded at the control. 3

15 DIMENSIONS 6 SERIES PROBE ASSEMBLIES.875 DIA. (73).8 (6) L H.8 (6) 3.5 (88.9).5 (.7) (5.) /-- NPT /--0 NC.375 (9.5) /-- NPSC WEEP HOLES (3) VIEW WITH COVER REMOVED.5 DIA. (5).37 (6.9).38 (6.9) VIEW WITH COVER REMOVED 3.5 DIA. /-- (76.) NPSC.8 (0.6) -- / NPT.65 (5.9).65 (5.9) 6BD 6LF -- / NPT Figure 6LJ 63 SERIES PROBE ASSEMBLIES #3--H UNION NUT (SUPPLIED BY CUSTOMER) PROBE WIRE TO CONTROL 6 SERIES PROBE ASSEMBLIES /--0 NC POLARIZED CONNECTOR (TO PREVENT INTERCHANGING OF PROBE WIRES) PROBE INSULATOR #5 UNION FERRULE (SUPPLIED BY CUSTOMER) *NOTE: FOR TYPES 63GJ AND 63GJ USE FITTINGS FOR TYPES 63GH AND 63GH USE / FITTINGS.5 (3.8) LENGTH TO BE SPECIFIED BY CUSTOMER.3 (7.9) ADAPTER NO. 36 S.S. 7/6 HEX (.) DIA. (7.) NO. 6 S.S. WIRE, INSULATED WITH GEON DIA. (.) PROBE TIP NO. 36 S.S. INSULATED A DIM..75 (9) HEX NUT, NO. 36 S.S. /--0 UNC.5 DIA. (6.35).56 DIA. (.3) SOLDER FERRULE TO TANK FOR MOUNTING FITTING INSULATOR (TO PREVENT PROBE RODS FROM TOUCHING) PROBE (CUT TO LENGTH ON INSTALLATION) 6 (5.).5 (8.6) (50.8) Figure 3 TYPE 63GJ 63GH TYPE 63GJ 63GH Figure 6CR

16 Power, Control and Information Solutions Headquarters Americas: Rockwell Automation, 0 South Second Street, Milwaukee, WI 530 USA, Tel : () , Fax : ().38. Europe/Middle East/Africa : Rockwell Automation, Vorstlaan/Boulevard du Souverain 36, 70 Brussels, Belgium, Tel : (3) , Fax (3) Asia Paci c : Rockwell Automation, Level, Core F, Cyberport 3, 00 Cyberport Road, Hong Kong, Tel : (85) , Fax : (85) Publication 3DJ--.0(B) February 996 Copyright 996 Allen-Bradley Company, Inc. Printed in USA