5300 Installation Manual - Spec
Contents
1. Diagram 53 4 Sensitivity Adjustment Type 53 1200 Relay only Approved Seal L A NON HAZARDOUS AREA HAZARDOUS AREA Class Il Ill Division 1 Groups A B C D E F G ELECTRODE HOLDER N O Relay Contacts close at this level N C contacts open Ground return to tank 1 or electrode if required q N O Relay Contacts open at this level N C contacts close Intrinsically Safe System Installation As defned by the National Electrical Code Factory Mutual and Underwriters Laboratories an intrinsically safe control system consists of equipment and associated wiring that are inherently incapable of releasing suffrient electrical or thermal energy under normal or abnormal conditions to cause ignition of a specift hazardous atmospheric mixture at its most easily ignited concentration in air Abnormal conditions would include any two independent mechanical or electrical faults occurring simultaneously such as accidental damage to any part of the equipment wiring and insulation and any other failure of electrical components due to application of over voltage improper adjustment or maintenance and other similar conditions When properly installed in accordance with the diagrams on page 2 B W 5300 Relays meet the most stringent requirements of FM and CSA for intrinsically safe operation from push buttons pressure or fbat switches thermostats humidistats or any other type of general purpose2. 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 Careful Wires Must Not Contact any Power Leads 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 5 Sensitivity Resistor Too Low If the sensitivity resistor value is too low for the resistance or conductivity of the liquid to be controlled the load relay will not pull in or it will buzz and chatter before pulling in In either case the relay should be replaced with a higher sensitivity relay see table page 1 If in doubt about sensitivity 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 diffrulty If unusual quantities of oil grease or sludge are encountered the electrodes can
3. hold in when the liquid leaves the lower electrode Control Repairs All B W Controls are tested at the factory prior to shipment to insure proper operation They should be handled with care during installation to avoid breaking electrical connections If the control does not operate properly after ithas been installed and service instructions indicate a defect repair should be attempted only at the factory due to the intrinsically safe rating on the relay 5300 Relay Dimensions 2 31 Va TE lt NIN S TS MYS OUI OUI O gt e Ee i a 21 TYP 4 62 250 Quick Connect 2 00 Terminals AMETEK AUTOMATION amp PROCESS TECHNOLOGIES Copyright 2005 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 5300 M1R 8 06 Z194 1M
4. pilot control device In addition they may also be actuated by probes or electrodes in contact with any conductive liquid or moist bulk material to perform a wide variety of mixing measuring metering and flow or level control functions In such installations inexpensive general purpose enclosures may be used for both the control relay and the pilot device and wiring between the two may be of any type approved for non hazardous locations without violating provisions of Article 500 517 of the National Electrical Code It is essential however that 1 an approved seal be used at the point where the intrinsically safe pilot control circuit enters the hazardous area and 2 the pilot circuit wiring be isolated from other wiring These instructions relate primarily to the B W electrode system of liquid level sensing See B W Form 465 for complete specifrations wiring and electrode equipment etc Electrode Lead Wires Shielded cable is not required Generally the size of the wire used is based upon the physical strength required to meet given installation conditions Size 14 to 18 gauge wire is generally strong enough for 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 Specia
5. a B W Controls LIQUID LEVEL TECHNOLOGY INSTALLATION amp SERVICE MANUAL 5300 intrinsically Safe Relays TO ee APPROVED 8 22219 4 LR 95564 Exia OVERVIEW Series 53 Controls Relays were developed especially to provide an intrinsically safe and economical means of detecting and controlling a wide range of processing variables in areas containing explosive atmospheric mixtures Tested and approved by FM and CSA for use in applications involving Class Il and III locations these compact solid state relays are designed to provide an external probe or pilot control circuit that is inherently incapable of releasing sufficient electrical energy to ignite even the most flammable gases or vapors classified in Groups A B C and D and combustible dusts or fibers classified in Groups E F and G Installation Options When mounted in an approved explosion proof enclosure B W Series 53 Relays can be located within a hazardous area providing the power wiring to the relay and from the load contacts is installed in accordance with applicable codes for the location The most economical method of installation however is to mount the relay in a non hazardous environment and run the external control circuit through an approved seal to a pilot device or level sensing electrodes in the hazardous area as shown in the diagrams on page 2 This permits use of low cost general purpose enclosures for both the relay and pilot device Ordina
6. 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 at the 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 flow 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 at a 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 15 and 16 either at terminal strip or electrode holder 2 Holding Circuit If the holding circuit terminals 15 16 is not closing the load relay will operate from the upper electrode only If the holding circuit is not opening the relay will operate from the lower electrode o
7. is safe to assume that a ground exists in the original wires to the electrode holder If the load relay does not pull in short the relay with a piece of insulated wire by bridging between relay terminals 14 amp 15 The load relay should dropout 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 the 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 2 000 feet between a 5300 control and the tank capacitance in the lead wires from the control to the electrodes may affect normal operation Check the chart on page 1 for maximum lead wire lengths Capacitance can cause the load relay to
8. ivity resistor on the control it is important that the sensitivity selected be rated higher than the resistance of the liquid or other sensing circuit The load relay is energized when the level sensing circuit is completed When operating from electrodes and liquid is below lower electrode a high resistance is sensed across terminals 14 amp 15 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 14 amp 15 and the signal to the SCR becomes positive or in phase turning the SCR on which in turn energizes the load relay When the load relay is energized an internal holding circuit contact closes to hold in the relay through the lower electrode and the liquid resistance unit liquid level falls below the lower electrode at which time the SCR turns off and de energizes the load relay TWO SWITCH OPERATION Fixed Sensitivity Control AC Line L r 115V or 230V 230V 1 t i 50 or 60 Hz Ev Chassis Ground pya I l b Normally Open Contacts Diagram 53 2 SERIES 53 Normally Closed Contacts RELAY 099 Approved Seal NON HAZARDOUS AREA HAZARDOUS AREA Class I Il Ill Division 1 PILOT SWITCHES TWO LEVEL OPERATION Fixed or Adjustable Sensitivity Control AC Line ack aa 230V 115V or 230V 2 1 Chassis Ground 50 or 60 Hz 115V Normally Open Contacts Normally Closed Contacts
9. l Note Electrode lead wires must not be run in the same conduit with power or load carrying circuits Electrode Lead Wire Length 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 sensitivity to assure positive operation over these extreme distances Refer to the 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 Ifa 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 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 posi
10. nly This holding circuit contact can be checked for continuity with an ohmmeter If defective the complete relay must be replaced C Intermittent Operation If control occasionally short cycles or operates intermittently check the following 1 Continuously monitor input voltage for fluctuations or voltage spikes 2 Check for physical vibration caused by contactors or magnetic starters mounted nearby 3 Check A 4 amp A 6 D Constant Chatter 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 14 amp 15 jumpered together the load relay is defective or the capacitor across the load relay coil may be defective In either case the complete relay should be replaced E Load Relay Will Not Drop 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 operation Careful Wires Must Not Contact Any Power Leads If load relay drops out properly it
11. ntrol are a transformer a circuit board with voltage divider circuit a silicon controlled rectifer SCR a feld effect transistor FET and a load relay to provide isolated DPDT contacts The sensing circuit voltage is 9 6 volts DC SINGLE SWITCH OPERATION Fixed Sensitivity Control AC Line _ _he_ r 115V or 230V 4 230V R O a l 50 or 60 Hz BV F Chassis Ground ae Naas A I l Normally Open Contacts Diagram 53 1 SERIES 53 Normally Closed Contacts RELAY PILOT SWITCH N O Relay Contacts close when pilot switch is closed N C Relay Contacts close when pilot switch is open SINGLE LEVEL OPERATING Fixed or Adjustable Sensitivity Control AC Line ak ope oe 230V HSV OF 290V J i a Chassis Ground 50 or 60 Hz 115V Normally Open Contacts Normally Closed Contacts Diagram 53 3 Sensitivity Adjustment Type 53 1200 Relay only NON HAZARDOUS AREA HAZARDOUS AREA Class Il IIl Division 1 Groups A B C D E F G ELECTRODE HOLDER Ground return to tank 7 or electrode if required N O Relay Contacts closed above this level N C Relay Contacts closed below this level A rectifer is used to convert the sensing circuit voltage from AC to 9 6 volts DC the FET is used to provide a high sensitivity This permits positive operation on liquids with very high resistance Since the voltage divider circuit compares the liquid resistance to an internal sensit
12. ry wires in conduit or an approved cable can be used for the intrinsically safe probe or pilot control circuit Moreover distance between the Series 53 Relay and the pilot device can be 10 000 feet or more depending on resistance and capacitance of the wires used for the external control circuit Basic Specifications Dual Voltage 115 or 230 VAC 50 60 Hz 10 20 Load Contacts Double pole double throw Contact Ratings 29 amperes resistive load at 120 or 277 VAC 1 hp at 120 VAC or 2 hp at 277 VAC 25 amperes resistive load at 28 VDC Power Required 9 volt amperes 6 watt max Control Circuit Inherently limited to less than a milliamp at 9 6 VDC to Energy assure intrinsically safe operation under abnormal fault conditions Relay Types and Options B W Series 53 Relays are supplied 25 amp load contacts and not recommended for use at less than 10 of their specified ratings The relays are also equipped with variable resistance potentiometer or choice of fixed resistors to meet the operating requirements of countless level sensing and pilot switching control applications Standard load contacts are more than adequate for most applications and in fact assure greater reliability where light loads and low voltages and currents are involved The higher rated power contacts are available to handle heavy duty loads but are not recommended for use at less than 10 of their specified ratings Operating sensitivit
13. strong alcohol solutions up to 50 ixed 820 000 ohms 5300 P F5 35 000 ft Deionized or distilled water 95 glycerine 90 peroxide 95 ethyl alcohol granular solids with moisture content 300 P F6 Fixed 2 2 megohms 12 000 ft Glacial acetic acid acetone granular solids with moisture content 300 P F7 Fixed 5 6 megohms 4 000 ft M E K Methyl Ethyl Keytone 5300 P F8 5300 P F4 Fixed 330 000 ohms 50 000 ft Alcohol solutions up to 70 P F Fixed 12 0 megohms 2 000 ft Anhydrous Ammonia Spec Tech Industrial 203 Vest Ave Valley Park MO 63088 Toll Free 888 SPECTECH Email sales spectechind com www spectechind com Principal of Operation B W 5300 Intrinsically Safe Relays are designed to operate on either 115 or 230 volts AC at 50 60 hertz The relay is 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 push buttons etc In addition the 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 The controls are also furnished with a fxed sensitivity resistor or a variable resistance potentiometer to permit adjustment of operation based on the resistance of the liquid or material to be controlled See table on page 1 The basic components of this co
14. tive operation and should not be altered or tampered with prior to installation If a control does not operate properly after it has been installed the following information will be helpful in determining the probable cause The load relay is energized when the liquid reaches the upper electrode or Unifbat reed switch level and electrode current is fbwing Be sure the relay lanes has been selected properly and a good ground connected to terminal 14 A Load Relay Will Not Pull In 1 Power Failure or No Voltage atAC Line Terminals Voltage at power input terminals should be 115 volts AC between terminals 11 amp 12 or 230 volts AC between terminals 11 amp 13 2 Defective Control To check control disconnect electrode and load connections from control terminals Apply line voltage to the appropriate terminals 11 12 or 11 13 and touch terminals 14 and 15 with an insulated jumper wire Load relay should pull in when the jumper is connect 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 14 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
15. y is important only in level control applications where the relay is operated from electrodes and the liquid is used as a conductor to complete the external sensing circuit Since liquid resistances vary several operating sensitivities are offered In such applications the relay must have sensitivity greater than the specific resistance of the liquid being controlled When operated from a B W Unifloat multi level sensing system or other pilot switching device a fixed 10 000 ohm sensitivity resistor is recommended Regardless of sensitivity ratings however all B W Series 53 Relays are designed to operate continuously with external probe or pilot circuit resistances as low as zero without damaging the relay This permits intrinsically safe operation at all times from electrodes or pilot switches Operating Sensitivity Operating Sensitivity Maximum Maximum Lead Application Recommendations Control Circuit Resistance Wire Lengths 5300 P V Variable 10 000 ohms to 1 megohm Same as F1 F5 Covers all applications described for F1 F5 5300 P F 1 Fixed 10 000 ohms 50 000 ft Unifloat and other dry contacts ordinary water with to high mineral content sewage water soluble oil solutions long distance applications 50 000 ft 5300 P F2 Fixed 22 000 ohms Water with low mineral content soft not distilled demineralized sugar syrup solutions long distance applications 5300 P F3 Fixed 68 000 ohms 50 000 ft Steam condensate corn syrup
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