MAN070 - Low Level Sensing System User Guide
Contents
1. Locate an appropriate place to operate your sensor system The SB 100 Controller should be mounted in an area that is easy to access and where there is a clear line of sight to the Warning Beacon NOTE Keep in mind the wire routing between the Material Reservoir SB 100 Controller and Warning Beacon when selecting your location Securely mount the Air Filter Regulator in an upright position Filter Bowl at the bottom Figure 5 Failing to securely mount the Air Filter Regulator in the upright position will prevent regulator from removing moisture and particulates from the incoming compressed air Find the length of 1 4 in 6 3 mm OD blue tubing without the fitting attached Connect a suitable length of this tubing from the Air Filter Regulator s Outlet Port to the Inlet port on the Air Precision Regulator by pushing the ends of the tubing into the fittings Figure 5 Ensure the Shutoff Valve on the Air Filter Regulator is in the closed position Connect your plant air supply to the Air Inlet on the Air Filter Regulator Figure 5 Air Filter Regulator Connection Dymax Low Level Sensing Systems User Guide Air Inlet Precision in 6 3 mm OD Air Line Shutoff Valve Air Outlet Filter Bowl Air Inlet Connect Supply Air Here Connecting Material Outlet Tube 1 Insert the 3 8 in 9 5 mm OD tubing through the push through fitting on the top of the Tank Cover Grab the tubing as it pr2. 6 Turn on the Beacon and Buzzer Functions on the SB 100 Controller 7 If no Buzzer Beacon Signal is observed loosen the locking screw and turn the Adjustment Dial Figure 7 located on the side of the Pressure Plate until the Sensor triggers Tighten lock screw to secure position 8 Ifthe Buzzer Beacon Signal is observed loosen locking screw and turn the Adjustment Dial Figure 7 until the buzzer beacon shuts off Tighten lock screw to secure position Figure 7 Pressure Plate Adjustment Knob Wheel 9 Place the Reservoir in the location used during normal operation Ensure the Tank is stable and level 10 Place the Pressure Plate Sensor in the bottom of the Tank It should be secure flat level and centered 11 Place a new full container in the Tank Make sure it is in the center of the Pressure Plate Sensor 12 Install the Reservoir Lid ensuring the Sensor Wire is fully inside of Tank and no pinching or kinking occurs Be certain not to pinch the Sensor Wire between the Reservoir Lid and Body 13 Secure the Reservoir Lid by tightening the Lid Hold Down Knobs evenly to ensure uniform sealing 14 With SB 100 Controller on adjust the functions to those preferred during operation See SB 100 Function Options page 20 Dymax Low Level Sensing Systems User Guide 15 Dispense normally Evaluate the initial trial to determine the time between sensor indication and container reaching complete empty level Adjust the sensor indica
3. Steps 4 6 to adjust the sensor height and evaluate indication preferences Replacing the Cartridge Reservoir WARNING some Dymax fluids can bond skin together in seconds It can also irritate skin eyes and mucous membranes To minimize the risk of bonded skin or irritation wear protective gloves and eyewear when working with Dymax fluids and the hand held spray gun system Remove the cover from the Reservoir Retainer by loosening the Cover Hold Down Knobs Remove the empty Cartridge Reservoir if present Remove the cover from the Cartridge Reservoir Place the Cartridge Reservoir in the Retainer so that the Fluid Outlet at the bottom of the Cartridge extends through the hole in the bottom of the Retainer Install the Retainer Cover on the Retainer Body and tighten the Cover s Hold Down Knobs To prevent low viscosity fluids from flowing out of the Cartridge Reservoir when the Outlet Plug is removed remove the Reservoir Retainer from the Lab Stand and hold the Retainer upside down Unscrew and remove the Plug from the Cartridge Reservoir Outlet Screw the 3 8 in 9 5 mm fitting into the Reservoir Outlet until it is just snug then turn it about one additional half turn NOTE Thread tape should be on the threads of the 3 8 in 9 5 mm fitting If the fitting does not have thread tape installed or you are reusing the fitting apply fresh thread tape to the fitting threads to prevent fluid leaks The 3 8 in 9 5 mm fittin
4. removed connect the Sensor Wiring to the connector in the lid Figure 6 Bottle Drop In Reservoir Configuration Wiring Route through Reservoir Lid to Controller Bulkhead Pass Through Fitting Pressure Plate 3 Strip the 1 4 in wire ends and secure the connections to the SB 100 Controller Ensure the Pressure Plate Sensor Connections are secure See Dymax Low Level Sensing Systems User Guide SB 100 Controller Setup page 19 4 Connect the Power Jack Beacon and any external controls to the SB 100 Terminal Connections See Dymax Low Level Sensing Systems User Guide SB 100 Controller Setup page 19 Setting Low Level Indication Level Calibrating the Sensor Plate requires adjusting the Sensor to the weight of the bottle when low level indication is preferred When bottle container types or material changes are made the Sensor must be re calibrated to compensate for the new weight 1 Placethe Pressure Plate Sensor on a level working surface near the Reservoir 2 Usethe EXACT bottle and material being dispensed 3 Slowly fill the empty bottle with material Fill to the level representing low and where operators would prefer low level indication to begin e g 1 of material in the bottom of the bottle 4 Place the bottle on the Pressure Plate Sensor Make sure the bottle is centered and stable on the Pressure Plate s surface 5 Turnon power to the SB 100 Controller
5. to read the material level in the cartridge 5 Depending on the rate and speed at which materials are being dispensed adjust the up down location of the Sensor within the Retainer Bracket Figure 4 so that it will provide enough warning time for operators The higher the Sensor is mounted in the Bracket the more time an operator will have to react before the cartridge runs out of material Setting the Sensor at the lowest point in the Bracket will result in minimal time between the warning and the cartridge reaching empty Figure 4 Sensor amp Adjustment Bracket on Cartridge Retainer Cartridge Retainer Retainer x Bracket Sensor Wiring N Blue Black Brown Sensor 6 Connect the power supply to the SB 100 Controller See Dymax Low Level Sensing Systems User Guide SB 100 Controller Setup page 19 7 Connect the Sensor Wiring to the SB 100 Terminal Connections See Dymax Low Level Sensing Systems User Guide SB 100 Controller Setup page 19 8 Turn the SB 100 Controller on and adjust the warning functions to those preferred during operation See Dymax Low Level Sensing Systems User Guide 10 SB 100 Controller page 19 Perform aninitial trial Dispense material until the level passes the Sensor to ensure the warnings are working properly Evaluate the time between the sensor indication and the container becoming completely empty Adjust the sensor indication levels as necessary repeat
6. 8 It is identified by a green Terminal Block and two Input Jack Terminals IMPORTANT Each terminal serves a specific function so connection to the proper terminal is critical in the proper operation and function of the level sensing system Figure 8 SB 100 Controller Connection Terminal Table 1 Controller Connections Type Terminal Figure 8 Description En nada iid Sensor Inputs 1 24 Brown Red If using two wires connect them to terminals 2 Ground Blue Black s three wires connect them to terminals 3 Signal Ground Black White 12 amp 3 Beacon Signal 4 24 Red Red 5 Ground Black Black PLC Logic Terminals 6 24 m 7 Ground Power Jack See label Aux Jack See label Dymax Low Level Sensing Systems User Guide SB 100 Function Options The SB 100 Controller is a flexible interface between sensors indicators and automation logic PLC platforms The SB 100 can be run in Driver or Driven mode supporting bench top to automated manufacturing environments The following is a review of functionality and connections required across these applications Low Level Detection amp Warning Only 1 2 Ensure the power input and appropriate terminal connections are secure Press the Power Button to turn on the Controller Select the Audio Buzzer Warning Button and the Beacon Button The Indicator Lights on the Controller should match Figure 9 Dispense material mak
7. Controller Select the Audio Buzzer Warning Button Beacon Button and Auto Shut Down button The Indicator Lights on the Controller should match 10 Connect the Aux Jack to an External Controller Dymax recommends using a DVC 345 Controller PN T11146 Dispense material making sure the material level in the Cartridge passes by the Sensor Eye Once the Sensor is tripped power to the External Controller will be automatically disconnected forcing the dispensing cycle to shut down Evaluate the sensor activation and warning functions Replace the empty Cartridge with a new full Cartridge of material See Replacing the Cartridge Reservoir on page 14 Power to External Controller will be automatically restored once the Cartridge is replaced Note The External Controller may need to be restarted after an auto shut down event The system is ready to dispense Figure 10 Indicator Lights when Power is On with Low Level Detection amp Warning Selected Dymax Low Level Sensing Systems User Guide Cleaning amp Maintenance System Cleaning Switching to a Different Fluid Since the level sensors do not contact fluid material the systems will work regardless of material When switching your system over from dispensing one fluid to dispensing a new fluid inspect that sensor surfaces are clean and free of obstruction If you are uncertain about material compatibility or sensor capacity contact Dymax Applicati
8. DENE dese ens Parts Included with Cartridge Reservoir Systems Parts Included with 1 Gallon Reservoir Systems iii Sensor Set Up amp Operation Cartridge Reservoir Systems se 12 Setting the Sensor Indication Level rtt Ne VROR RR dg KR ME snes ARES RE REOR RON NR EE QR ERR RR s se 12 Replacing the Cartridge Reservolt 2 3 diete Rete intensa inania eei pieta A a resa sd trier Pac tea E HR PERROS 14 Sensor Set Up amp Operation Bottle Drop In Reservoir Systems 14 Connecting Air Regulators and Material Line to the Tank Cover 15 Connecting Material Outlet Tu be tesi terit iam Tae A serta er Ehre d dee ener er adera ara E eee stone 15 Installing Pressure Plate Sensor Assembly id es 16 Setting Low Level Indication Level 17 Inserting the Bottle Reservoir in the Tank deett petiere tete een cete aiio E kae eU Hie eed e EcL ee eq ts 18 SB 100 Controller Setup Connecting the Sensor to the SB 100 Controller SB 100 Function OPTIONS mee pc E Cleaning amp MaiNtOnanCe TETTE TII III 22 SVSteriaiGl Qa rites utr D oen IEEE ient eMe E 22 Periodic Sensor Maintenance eri HE serie eb HEC ET edere di ied teehee Pe e EE MC be un Lu Ee ed aS 22 Troubleshooting eite teet eta ote hnic ken Cota e Ere naci Re Cua edP e cae seseris Te cna cP Pe ceased Pe Haa cras rene c 23 Spare Parts and Accessories Spar Replacements Parts lt i em step EIN pa NM DM Specifications eeriessee
9. ITTEN AUTHORIZATION FROM DYMAX THOSE CORRECTIVE ACTIONS LISTED ABOVE ARE LIMITED TO THIS AUTHORIZATION Index Accessories 24 Assembly Bottle drop In Reservoirs 15 Cartridge Reservoir Systems 12 Cartridge Reservoir Replacement 13 Cleaning 22 Connections SB 100 Controller 19 Controller Settings 20 Help 4 Main Components 9 Maintenance 22 Parts List 12 PLC Automation Logic Integration 21 Product Overview 8 Dymax Low Level Sensing Systems User Guide Safety 4 5 Using Safe Operating Pressures 5 Settings Sensor Indication Level 12 Spare Parts 24 Specifications 25 Air Regulator Specifications 25 Materials of Construction 25 Operating Specifications 25 Reservoir Specifications 25 Support 4 Troubleshooting 23 Unpacking 12 Utilities 8 Warranty 26 2014 Dymax Corporation All rights reserved All trademarks in this guide except where noted are the property of or used under license by Dymax Corporation U S A Please note that most dispensing and curing system applications are unique Dymax does not warrant the fitness of the product for the intended application Any warranty applicable to the product its application and use is strictly limited to that contained in Dymax standard Conditions of Sale published on our website at www dymax com pdf Conditions of Sale pdf Dymax recommends that any intended application be evaluated and tested by the user to ensure that desired performance
10. Low Level Sensing Systems User Guide Cartridge Reservoirs or Bottle Drop In Tanks with Low Level Sensor Systems m Instructions for Safe Use m Setup and Operation m Maintenance m Ordering Spare Parts and Accessories Dymax Low Level Sensing Systems User Guide About Dymax UV Visible light curable adhesives Systems for light curing fluid dispensing and fluid packaging Dymax manufactures industrial adhesives light curable adhesives epoxy resins cyanoacrylates and activator cured adhesives We also manufacture a complete line of manual fluid dispensing systems automatic fluid dispensing systems and light curing systems Light curing systems include LED light sources spot flood and conveyor systems designed for compatibility and high performance with Dymax adhesives Dymax adhesives and light curing systems optimize the speed of automated assembly allow for 100 in line inspection and increase throughput System designs enable stand alone configuration or integration into your existing assembly line Please note that most dispensing and curing system applications are unique Dymax does not warrant the fitness of the product for the intended application Any warranty applicable to the product its application and use is strictly limited to that contained in the Dymax standard Conditions of Sale Dymax recommends that any intended application be evaluated and tested by the user to i
11. Reservoirs Problem Possible Cause Tank does not maintain pressure Bent Air Supply Line Corrective Action Inspect the Air Supply Line Straighten and remove any kinks in the Air Supply Line Damaged Air Regulator Install a new Air Regulator Damaged Cover U Cup Seal Replace the damaged U Cup Seal The Cover is not secured Tighten all knobs on the cover to secure Damaged Air Relief Valve Replace the Air Relief Valve The Sensor Wire is pinched Ensure the Sensor Wire is inside Tank free and clear of the Cover SB 100 indicators not SB 100 function turned off working Press the Function Button to turn on off indicators SB 100 alarm sounding Check wiring for crossed terminal connections Material not flowing Material viscosity is too high Increase the system s inlet fluid pressure Material Dispense Tube is too long Shorten the length of material tube Material cured blocked in tube Clean or replace tubing Inconsistent level New bottle container styles being used Re calibrate the Plate Sensor to the desired level indications Bottles Containers are not exact Ensure the bottles containers are exactly the same style weight The Pressure Plate s travel is impeded Check that Sensor components are moving freely and the Material Dip Tube is not interfering with the bottle s bottom surface Dymax Low Level Sensing Systems User Guide Spare Pa
12. criteria are satisfied Dymax is willing to assist users in their performance testing and evaluation Data sheets are available for valve controllers or pressure pots upon request Dymax Corporation 860 482 1010 info dymax com www dymax com Dymax Korea LLC 82 2 784 3434 info_kr dymax com www dymax com kr Dymax Oligomers amp Coatings 860 626 7006 oligomers amp coatings dymax com www dymax oc com Dymax Europe GmbH 49 0 611 962 7900 info_de dymax com www dymax de Dymax UV Adhesives amp Equipment Shanghai Co Ltd 86 21 37285759 dymaxasia dymax com www dymax com cn Dymax UV Adhesives amp Equipment Shenzhen Co Ltd 86 755 83485759 dymaxasia dymax com www dymax com cn T17974 MANO70 8 12 2014 Dymax Asia H K Limited 852 2460 7038 dymaxasia dymax com www dymax com cn Dymax Asia Pacific Pte Ltd 65 6752 2887 info_ap dymax com www dymax ap com
13. d with 1 Gallon Reservoir Systems m Bottle Drop In Material Reservoir with pass through fits 0 26 gal 1 L and 0 5 gal 2 L bottles or 0 26 gal 1 L 0 5 gal 2 L and 1 0 gal 3 78 L bottles m SB 100controller m Platesensor assembly m Power supply 100 240V 50 60Hz 0 6A m Remote beacon m Aux jack cable Sensor Set Up amp Operation Cartridge Reservoir Systems Assembling a cartridge reservoir system involves setting the appropriate sensor indication level and determining the level of logic and function required for the SB 100 controller Setting the Sensor Indication Level 1 Locate an appropriate place to operate your sensor system The SB 100 Controller should be mounted in an area that is easy to access and where there is a clear line of sight to the Warning Beacon Dymax Low Level Sensing Systems User Guide NOTE Keep in mind the wire routing between the Cartridge Retainer SB 100 Controller and Warning Beacon when selecting your location 2 With the Cartridge Retainer and Sensor in place insert a cartridge of material into the Retainer For initial setup it is recommended that a cartridge be filled with water and sealed with piston This minimizes time cleanup and saves material 3 Sealthe Retainer Cap and attach the Fluid Outlet Tube to a controlled Dispense Valve 4 Ensure the Sensor is pressing tightly against the plastic cartridge wall Without physical contact the capacitive sensor will not be able
14. ding and understanding the information in this guide personal injury can result from the uncontrolled release of high pressure gas injection or exposure to chemicals To reduce the risk of injury read and understand this guide before assembling and using the Dymax fluid dispensing system General Safety Considerations All users of Dymax equipment systems should read and understand this user guide before assembling and using the system To learn about the safe handling and use of dispensing fluids obtain and read the Material Safety Data Sheet and handling requirements for each fluid before using the fluid Dymax includes a Material Data Safety Sheet with each adhesive we sell You can also request Material Safety Data Sheets for our products on our website Dymax Low Level Sensing Systems User Guide Specific Safety Considerations Using Safe Operating Pressures Pressurizing the components in the dispensing system beyond the maximum recommended pressure can result in the rupturing of components and serious personal injury To minimize the risk of rupturing components and injury do not exceed the maximum operating pressure of the components in your fluid dispensing system See system specifications Replacing System Parts When replacing system parts ensure the quality of replacement parts matches the quality of the original equipment parts to maintain the safety and operational performance of the system Bottle Drop In Tank Potent
15. ea while operating or if fumes are present Do not operate a gasoline engine in the work area Chemical WARNINGS Hazardous chemicals can give off fumes that can cause serious injury or death if inhaled swallowed or splashed in the eyes or on the skin Wear respiratory protection and protective eyewear gloves and clothing Consult the chemical manufacturer for recommended personal protective equipment and hazards specific to the chemical being used Fumes may contain both gases vapors and dust smoke given off by a substance as a result of a chemical transformation Consult the Material Safety Data Sheet MSDS or Safety Data Sheet SDS for all chemical products you are using prior to commencing work Store hazardous chemicals in approved containers Dispose of hazardous chemicals according to all local state and federal regulations m Dymax Low Level Sensing Systems User Guide Product Overview Description of the Dymax Low Level Sensing System Dymax low level detection systems allow users to accurately monitor material levels during the dispensing process with an adjustable sensor mount The level sensors are intended to be used with pressurized reservoirs Two sensor system configurations are available allowing integration into cartridge reservoirs or pressure pot material reservoirs Both configurations feature an SB 100 controller which activates a warning beacon buzzer when the material level in the reservoir reac
16. eservoir Never use 1 1 1 trichloroethane methylene chloride or other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment Use in pressurized equipment could result in a chemical reaction with the possibility of explosion Comply with all applicable fire electrical and safety regulations Dymax Low Level Sensing Systems User Guide Tipping and Dropping Tubing WARNINGS Place the equipment on a sturdy level surface Check that all tubing lengths are long enough to allow for unrestricted movement of the system components Do not lift pressurized equipment If the equipment needs to be moved do not pull on the tubing to move the reservoir Do not tip the reservoir or place it on its side Fluid can enter and damage the pressure regulator and the pressure relief valve leading to an over pressure condition within the reservoir Once the pressure regulator and or pressure relief valve become blocked they must be replaced with new Dymax parts before the equipment can be operated again Do not drop the pressure tank Dropping a pressure tank from any height can damage the pressure relief valve pressure regulator fittings reservoir body or cover A damaged pressure regulator or damaged pressure relief valve may lead to an over pressure condition within the reservoir while a damaged reservoir body or cover can lead to an explosion If your reservoir is dropped it must be thorou
17. etting is simply controlled as an on off function by pressing on the appropriate button When a button is in the on position the LED indication light above the button will be illuminated When the material level reaches the set low point the LED light in the top right corner of the controller will turn on automatically Figure 1 SB 100 Controller Connect Sensor Wiring Terminal Block Power Jack Aux Jack Low Level Reached Indication Light Red LED Indicator Lights Green When Selected On Off Auto Shut Down Auto Buzzer Beacon Dymax Low Level Sensing Systems User Guide Cartridge Reservoir Assembly A cartridge reservoir assembly consists of a metal cartridge retainer and a polyethylene cartridge reservoir The retainer cover seals the top of the cartridge reservoir The bottom of the retainer includes a hole from which the outlet port of the cartridge reservoir protrudes Pressurizing the top of the retainer pushes the cartridge reservoir piston down which pushes the fluid from the outlet port Cartridge reservoir retainers are supplied in three sizes but the design features of each are similar Each cartridge reservoir retainer includes one empty reusable cartridge reservoir that can be filled with fluid for dispensing Level sensing retainers accept the same cartridges as standard retainers A sensor is seated into a bracket formed directly into t
18. g is specially designed to fit the Cartridge Reservoir Outlet The bottom three threads are machined from the fitting Using a standard fitting in place of the Dymax supplied fitting will split the Cartridge Outlet Port and lead to fluid leaks Use only the Dymax supplied fitting on the Outlet Port of a Cartridge Reservoir For optimal dispensing performance the length of all fluid lines should be as short as possible to reduce fluid pressure drop and other variations that may affect precision dispensing Dymax Low Level Sensing Systems User Guide Sensor Setup amp Operation Bottle Drop In Reservoir Systems Assembling the low level pressure plate sensor into a bottle reservoir system involves completing four main processes Connecting all regulators air lines and fluid output tubing Ref Bottle Drop In User Manual Connecting the pressure plate sensor wiring to SB 100 controller through reservoir lid bulkhead fitting Setting preferred point for sensor low level indication Inserting the pressure plate sensor and bottle reservoir in the tank NOTES Ensure that you plumb the air lines correctly at the inlets and outlets of the dispensing system components The dispensing system will not function properly if you plumb the compressed air lines incorrectly Ensure that the bottle or container to be used in the 1 gallon tank does not exceed 12 inches in height Connecting Air Regulators and Material Line to the Tank Cover 1 4 5
19. ghly inspected for any cracks or damage to the pressure regulator and or pressure relief valve Any damaged parts must be replaced with Dymax parts before the equipment can be operated again If you are unsure about the condition of your tank please contact Dymax WARNINGS Pressurized tubing can be very dangerous Worn damaged or misused tubing can develop a leak spraying the contents of the tank at high pressure Materials can be sprayed into eyes or onto skin causing serious bodily harm Fire and other property damage can also occur from unwanted spraying Before pressurizing the system make sure all fluid connections to the tank are secure and route tubing away from traffic areas sharp edges moving parts and hot surfaces Inspect all tubing for cuts leaks or other damage and replace any damaged tubing immediately Check that the material being dispensed is compatible with the tubing material Contact Dymax Applications Engineering if you are unsure of tubing material compatibility Do not expose tubing to operating temperatures above 50 C 122 F or below 0 C 32 F Pressurized Equipment WARNINGS Ruptured components in pressurized systems can spray or splash materials on the skin or in the eyes causing serious injury Do not try to stop or repel fluid leaks with your hand body glove or rag In the event of a ruptured component stop work immediately close tank inlet valve depressurize the tank and disconnect the air sup
20. he lower portion of the retainer The sensor is adjustable within this bracket Once set at a desired position the sensor detects when fluid level passes by the detection point and triggers audio and visual warnings through the SB 100 controller The controller can also be set to automatically shut down a production line if the reservoir is empty Figure 2 Cartridge Reservoir Assembly with Low Level Sensor Regulated Compressed Air Inlet Cover Hold Down Knob Lab Stand Locking Knob Retainer Cover Cartridge Reservoir Retainer Specially designed for level sensor applications The retainer holds and maintains contact between the cartridge reservoir and the sensor assembly Sensor Wiring Low Level Sensor 3 wire to SB 100 Controller Fluid Dispensing Line Hole where the outlet of the Cartridge Reservoir protrudes for connection to the Fluid Dispensing Line Fluid Out Dymax Low Level Sensing Systems User Guide Bottle Drop In Material Reservoir Bottle drop in material reservoirs include a push through fitting on the tank cover where a fluid dispensing line is pushed directly through the fitting and into the tank to form a draw tube When the tank is pressurized the fluid is pushed up the tube and into the fluid dispensing line A precision air regulator is permanently attached to the cover of the tank for easy monitoring of pressure Level sensing is achieved with the addition of a pressure plate that rests o
21. hes a specified low level The SB 100 controller also features an external PLC connection that allows for a total line shut down Both functions save time and money by stopping the dispensing system when material is empty Each sensor configuration is adjustable allowing users to set specific levels of material to signal warning and automatic shut off options Features amp Benefits Features Benefits No wetted components sensor does not contact fluids Level sensor is compatible with wide range of materials Accurate sensor detection Hysteresis 5 Dependable repeatability of accurate sensing level Easy adjustment Greater dispensing accuracy with quick level setting Low electrical power required SB 100 smart monitor nM um Prevents air from entering into fluid lines Ergonomic accessible sensor locations for quick adjustment Easy access to sensors PARE amp visual verification of placement Utilities Required The level sensing system is designed to work within pressurized containers up to 100 psi 6 9 bar as well as freestanding containers The sensors and SB 100 controller is complete with power source Power Source Specs Input range 100 240V 50 60Hz 0 6A Output 24V 0 75A Dymax Low Level Sensing Systems User Guide SS Main System Components SB 100 Controller The SB 100 controller interface controls power on off auto shut down auxiliary jack internal audio alarm and external beacon alarm Each s
22. ial Hazards Equipment Misuse WARNINGS This equipment is for professional use only Serious injury can result from high pressure fluids To reduce the risk of injury read and ensure you understand the information in this user guide before assembling and operating the Dymax pressure tank Read all instructions before operating the equipment Use the equipment for its intended purpose only If you are uncertain about usage call Dymax Application Engineering before continuing Improper use such as modifying or removing parts using incompatible materials over pressurizing the equipment or using worn damaged incompatible parts can result in serious bodily injury Do not alter or modify this equipment in any way If worn parts need to be replaced use only Dymax parts and accessories Inspect all equipment components daily Repair or replace any worn or damaged parts immediately Do not use the equipment until any worn or damaged parts have been replaced Use materials which are compatible with the equipment s wetted parts Reference the material manufacturer s warnings If you are unsure about material compatibility contact Dymax Application Engineering Do not exceed the maximum working pressure of the lowest rated system component This pressure tank has a 60 psi 410 kPa 0 41 MPa 4 1 bar maximum working pressure Check the rating on all dispensing equipment and accessories to ensure they can withstand the operating pressure of the r
23. ing sure the material level in the cartridge passes by the Sensor Eye Evaluate the sensor activation and warning functions Replace the empty cartridge with a new full cartridge of material See Replacing the Cartridge Reservoir on page 14 The system is ready to dispense Figure 9 Indicator Lights when Power is On with Low Level Detection amp Warning Selected Low Level Detection with PLC Automation Logic 1 2 Ensure power input and appropriate terminal connections are secure Press the Power Button to turn on the Controller Select the Audio Buzzer Warning Button and Beacon Button The Indicator Lights on the Controller should match Figure 9 Connect the SB 100 Terminals to an External PLC or Automation Logic Control Note PLC output is a N O normally open design Set the PLC Automation Control to immediate or timed shut down action based on the signal received from the SB 100 Dymax Low Level Sensing Systems User Guide Dispense material making sure the material level in the cartridge passes by the Sensor Eye Evaluate the sensor activation and warning functions Replace the empty cartridge with a new full cartridge of material See Replacing the Cartridge Reservoir on page 14 The system is ready to dispense Low Level Detection Warning and Auto Shutdown 1 2 Ensure power input and appropriate terminal connections are secure Press the Power Button to turn on the
24. n the bottom of the tank When material in the bottle reaches a certain level weight the sensor will send a signal to the SB 100 controller notifying user that material level is low Figure 3 1 Gallon Bottle Drop In Tank with Low Level Sensor A Pressure Gauge Compressed Air In SI from Filter Regulator Fluid Outlet Port and Push Through Fitting Pressure Adjustment Knob Pressure Relief Valve Air Precision Regulator Hold Down Knob for Lid Fluid Out Reservoir Lid Sensor Wiring Pass Through Bottle Drop In Sensor Wiring Reservoir Connects to Controller Pressure Plate Dymax Low Level Sensing Systems User Guide Unpacking Unpacking and Inspecting Your Shipment When your low level sensing system arrives inspect the box for damage and notify the shipper of box damage immediately Open the box and check for equipment damage If parts are damaged notify the shipper and submit a claim for the damaged parts Contact Dymax so that new parts can be shipped to you immediately Check that the parts included in your order match those listed below If parts are missing contact your local Dymax representative or Dymax Customer Support to resolve the problem Parts Included with Cartridge Reservoir Systems m Cartridge reservoir with sensor mounts 12 oz 20 oz or 32 oz m SB 100controller m Sensor assembly m Power supply 100 240V 50 60Hz 0 6A m Remote beacon m Aux jack cable Parts Include
25. nded Pressure gauge installed from factory 80 psi 5 5 bar adjust as required if installed Main System Air Regulator Pressure gauge installed from factory 80 psi 5 5 bar Precision Air Regulator for Material This regulator controls the pressure on the material Set at 15 psi 1 bar for materials under 10 000 cP and 30 psi 2 1 bar for materials over 10 000 cP Reservoir Retainer Tank Sizes Cartridge retainers hold 120z 300 mL 20 oz 550 mL and 320z 900 mL reservoirs Bottle reservoir tank holds 0 26 gal 1 L and 0 5 gal 2 L and 1gal 3 75 L bottle reservoirs Air Precision Regulator Pressure Gauges Pressure gauge installed from factory 0 to 60 psi 0 to 4 1 bar Alternative gauges supplied 0 to 30 psi and O to 100 psi 0 to 2 1 bar and 0 to 6 9 bar Dymax Low Level Sensing Systems User Guide Warranty From date of purchase Dymax Corporation offers a one year warranty against defects in material and workmanship on all system components with proof of purchase and purchase date Unauthorized repair modification or improper use of equipment may void your warranty benefits The use of aftermarket replacement parts not supplied or approved by Dymax Corporation will void any effective warranties and may result in damage to the equipment IMPORTANT NOTE DYMAX CORPORATION RESERVES THE RIGHT TO INVALIDATE ANY WARRANTIES EXPRESSED OR IMPLIED DUE TO ANY REPAIRS PERFORMED OR ATTEMPTED ON DYMAX EQUIPMENT WITHOUT WR
26. nsure that desired performance criteria are satisfied Dymax is willing to assist users in their performance testing and evaluation Data sheets are available for valve controllers or pressure pots upon request Dymax Low Level Sensing Systems User Guide Contents IMEFODUCHON m 4 Introduction to the User G ide erede vena les eva i te e aaa rae a Roa cade nei ana poe Aa Aera Ee eda Rex inna init 4 Where to Get llelp ii EE EE A bes Pe abesse snas ap ede has inerte A edu tae raa aa PRX time ins 4 MEHR 4 General Safety Considerations reip ecco OaE OAE AAE TEE aE Ae RAF Ren REM Ee nt ERE RACK X nex Een pe xS 4 Specific Safety Considerations esse 5 Bottle Drop li Tank Potential H zards iie eei nn o tRn ted uini qne ESPERE CE RR RN Rae kao ENSE RD EARE AER EEE E 5 Product OVERVIEW t 8 Description of the Dymax Low Level Sensing System 8 Utilities Required ant tait ne CNO 8 Main System Compotients eerie rone EE ee SEE Ee ERR A XE e WERE Ee MEYER MERE EYE En EXER TV XN net ee entente 9 Unpacking PR a R a Aa a aa a aAA NEREA Unpacking and Inspecting Your Shipments intret terree ees ene e dte vie Vae VUNENE NE
27. on Engineering for assistance Periodic Sensor Maintenance Using a damp cloth clean the cartridge sensor periodically with benign solvent or Isopropyl Alcohol to ensure contacts are free of debris Using a damp cloth clean the tank pressure plate periodically with benign solvent or Isopropyl Alcohol to ensure the mechanism is clear of debris and maintains free range of motion Do not soak or submerse sensors in liquid Ensure ALL power is disconnected from SB 100 and sensors before cleaning Troubleshooting Dymax Low Level Sensing Systems User Guide Table 2 FAQ s Low Level Sensing Systems with Cartridge Retainers Problem Possible Cause Sensor is not detecting fluid levels Sensor is not securely in contact with cartridge Corrective Action Tighten connection between retainer sensor cartridge Sensor not signaling or random signaling Check continuity between sensor and controller Material remaining on walls of cartridge Check piston sizing ensure wiper is fully cleaning material from walls during dispense SB 100 indicators not working SB 100 function turned off Press function button to turn on off indicators Sensor moving during operation Sensor bracket loose Tighten sensor bracket fasteners Retainer bracket shows hairline stress cracks Retainer air pressure too high Reduce air pressure psi Table 3 FAQ s Low Level Sensing Systems with Bottle Drop In Material
28. otrudes on the underside of the Tank Cover and pull the tubing through to form a Dip Tube The Dip Tube should be of sufficient length to reach the bottom of the bottle or container when placed on the Level Sensor Plate The exact distance from the Tank Cover to the Pressure Plate in the at rest position is 12 5 in 31 75 cm IMPORTANT Ensure tube is long enough to reach the bottom of the bottle without pressing downward on the bottle s bottom surface If tube is cut too long it will interfere with the Level Sensor Plate s function TIP Cut the end of the tube at a 45 angle to ensure free flow of material at the bottom of the reservoir Cut the other end of the Fluid Dispensing Line to a working length 6 ft or less recommended The dispensing line should be cut as short as possible to reduce pressure losses in the line but long enough to enable you to reach and work comfortably in the work area Connect the Fluid Dispensing Line to dispensing equipment via press fit or compression fitting NOTE For optimal dispensing performance the length of all fluid lines should be as short as possible to reduce fluid pressure drop and other variations that may affect precision dispensing Installing Pressure Plate Sensor Assembly 1 Open the Bottle Drop In Reservoir and place the Pressure Plate Sensor Assembly inside Rest it evenly on the bottom of the Tank Figure 6 Dymax Low Level Sensing Systems User Guide 2 With the Reservoir Lid
29. ply Any damaged parts must be replaced with Dymax parts before the equipment can be operated again Follow the pressure relief procedure whenever you are instructed to relieve the pressure stop dispensing clean check or service equipment or install or clean the fluid nozzle Tighten all the fluid connections before operating the equipment Inspect the fluid line tubing and couplings daily for damage or wear Replace worn damaged or loose parts immediately Dymax Low Level Sensing Systems User Guide Fire and Explosion For Spraying Applications WARNINGS Ground all equipment in the work area Improper grounding poor ventilation open flames or sparks can cause hazardous conditions and result in a fire explosion or other serious injury If static sparking occurs or an electric shock is felt while using the equipment stop spraying immediately Do not use the equipment until you identify and correct the problem Always work in a well ventilated area Some materials give off flammable fumes or vapors Upon buildup these fumes can result in a fire or explosion Keep the work area free of debris i e solvents rags gasoline Always keep a fire extinguisher compatible with your equipment and processes in the work area in case of fire Electrically disconnect all the equipment in the spray area and extinguish all open flames or pilot lights Do not smoke in the work area Do not turn on or off any light switch in the work ar
30. rts and Accessories Spare Replacements Parts Item Part Number Cartridge Reservoir Systems Spare Parts Cartridge Sensor w mount screws T18085 Reservoir Sensor Plate 12 oz w mount screws T18086 Low Level Res 120z Main T17944 Low Level Res 120z MOD T17926 Low Level Res 200z Main T17967 Low Level Res 320z Main T17976 Aux Cable Assembly T17981 Bottle Drop In Material Reservoir System Spare Parts Bulkhead Pass Thru Fitting T17964 Adapter Tee T17965 Cable Assembly T17978 Low Level Plate Assembly for 1 Gallon Bottle Drop In Tank T17979 1 Gallon Bottle Drop In Reservoir Tank Main T17984 Universal SB 100 Controller amp Indicator Parts SB 100 Controller T17969 Low Level Beacon T17968 Power Supply T11624 Dymax Low Level Sensing Systems User Guide Specifications System Specifications Materials of Construction Cartridge sensor Polypropylene stainless steel Tank plate sensor 304 stainless steel SB 100 ABS plastic internal PCB amp Polypropylene connectors Fluid tubing light blocking black polyethylene Teflon Fluid tubing fittings acetal stainless steel Dymax fluid reservoirs cartridge bottles and pails polyethylene Dymax fluid reservoir piston on cartridge reservoirs only polyethylene Operating Specifications Recommended clean dry compressed air supply to main regulator 80 psi 5 5 bar 120psi 8 3bar using air filter regulator below Air Filter Regulator with Dump Valve Recomme
31. sesenta pea a eau rakin saaran Re NR ER NR Saras APOS SPAS RRSNRRRRRRe Sa REN RR eRRRe NR Resa aea RERRRSRRRR RR es tte etes sectes NAROS 25 System Specifications toc eerte pad ei tote ep es eden dense rates OI DH E TER UR ETE ee 25 MEC PP PR Rene 26 EU Dymax Low Level Sensing Systems User Guide Introduction Introduction to the User Guide This guide describes how to use Dymax Low Level Sensing Systems Sections in this guide describe how to assemble use and maintain the equipment safely and efficiently Intended Audience Dymax prepared this user guide for experienced process engineers technicians and manufacturing personnel If you do not understand the instructions contact Dymax Application Engineering to answer your questions before using the equipment Where to Get Help Additional resources are available to ensure a trouble free experience with our products m Detailed product information on www dymax com m Dymax Customer Support and Application Engineering teams are available in the United States Monday through Friday from 8 00 a m to 5 30 p m Eastern Standard Time You can also email Dymax at info dymax com Contact information for additional Dymax locations can be found on the back cover of this user guide m Dymax adhesive Product Data Sheets PDS on our website m Material Safety Data Sheets MSDS provided with shipments of Dymax adhesives Safety WARNING if you use this equipment without first rea
32. tion levels as necessary repeat Steps 2 7 to adjust the sensor indication level Inserting the Bottle Reservoir in the Tank WARNING some Dymax fluids can bond skin together in seconds It can also irritate skin eyes and mucous membranes To minimize the risk of bonded skin or irritation wear protective gloves and eyewear when working with Dymax fluids and the hand held spray gun system NOTE Exposing Dymax adhesives to light causes most Dymax adhesives and fluids to begin curing Hence to prevent unintentional curing during the loading of bottle reservoirs have the reservoir tank ready to accept the bottle reservoir and complete the loading process quickly after opening the bottle reservoir 1 Removethe Lid from the Bottle Reservoir Tank by loosening the Lid Hold Down Knobs 2 Unscrew the Lid from a 0 26 gal 1 L or 0 5 gal 2 L Bottle Reservoir and place the Reservoir into the Tank Complete this step quickly to prevent initiation and curing of light sensitive fluids 3 Install the Reservoir Lid on the Tank ensuring the Dip Tube is inserted to the bottom of the Bottle Reservoir Complete this step quickly to prevent curing of light sensitive fluids 4 Tighten the Lid Hold Down Knobs evenly to ensure uniform sealing Dymax Low Level Sensing Systems User Guide SB 100 Controller Setup Connecting the Sensor to the SB 100 Controller The SB 100 s Connection Terminal is located on the top face of the Controller Figure
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