AMETEK 5200 Solid State Relay User Manual

Page 2

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.

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.

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.

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.

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.

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Sensitivity Ranges

Relay Type R1 Resistor Direct Operation

Inverse Operation

5200-LF1

Fixed R1

Resistor

Up to 16,000 ohms

Up to 26,000 ohms

5200-LV1

Variable

100 to 700 ohms

200 to 1,200 ohms

5200-LV2

Variable

600 to 15,000 ohms

1,000 to 24,000 ohms

5200-HF2

Fixed R1

Resistor

Up to 11.6 megohms

Up to 12.0 megohms

5200-HV3

Variable

2,000 to 100,000 ohms 2,000 to 100,000 ohms

5200-HV4

Variable

.007 to 1.0 megohms

5200-HV5

Variable

.047 to 5.0 megohms

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

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