Henkel BONDERITE E-CO Series Manual de usuario

E-CO Level Control,

120 VAC, One, Two, Three, and Four Points

Operating Manual

Table of Contents

1Please Observe the Following ........................................................................................................................ 1

1.1Emphasized Sections ................................................................................................................................ 1

1.2For Your Safety ........................................................................................................................................... 1

1.3Unpacking and Inspection ...................................................................................................................... 2

1.4Items supplied ............................................................................................................................................ 2

1.5Features ........................................................................................................................................................ 2

2Description .......................................................................................................................................................... 3

3Technical Data .................................................................................................................................................... 4

3.1 Utilities ................................................................................................................................................................. 4

3.2 E-CO Level Control Unit Overall & Mounting Dimensions ................................................................ 4

3.3 General Arrangement .................................................................................................................................... 5

4Installation ........................................................................................................................................................... 6

4.1Electrical ........................................................................................................................................................7

4.2Air Probe ...................................................................................................................................................... 8

4.2Solenoid Valves .......................................................................................................................................... 9

5Operation ............................................................................................................................................................ 10

5.1 Indicator Light – color and function ......................................................................................................... 10

5.2 Adjusting Master Air Pressure Switch ...................................................................................................... 10

5.3 Adjusting Regulator Pressure on Master Level Control ..................................................................... 11

5.3 Adjusting Flow Regulator ............................................................................................................................ 11

5.4 Adjusting Air Differential Pressure Switch for Level ............................................................................ 13

5.5 One Point Level Control for Low Level Shut-Off for Drums, Totes, or Day Tanks .................... 14

6Troubleshooting ............................................................................................................................................... 15

7Care and Maintenance ................................................................................................................................... 16

7.1 Master Air Pressure Switch .......................................................................................................................... 16

7.2 Master Air Pressure Regulator/Filter ........................................................................................................ 17

7.3 Flow Regulator ................................................................................................................................................ 17

7.4 Differential Pressure Switch ........................................................................................................................ 18

8Accessories and Spare Parts ......................................................................................................................... 19

9Diagrams ............................................................................................................................................................ 20

9.12251341 REV - E-CO Level MSTR 1 PT - electrical ......................................................................... 20

9.22250048 REV - E-CO Level STD 1 PT - electrical ........................................................................... 20

9.32251340 REV - E-CO Level MSTR 2 PT - electrical ........................................................................ 21

9.42251339 REV - E-CO Level STD 2 PT - electrical ........................................................................... 22

9.58907225 Master Level Control Three Point - electrical ............................................................... 23

9.68907224 Standard Level Control Three Point - electrical .......................................................... 24

9.78907227 Master Level Control Four Point - electrical ................................................................. 25

9.88907226 Standard Level Control Four Point - electrical ............................................................. 26

9.9Level Control Standard and Master Installation Drawing 8907228 ......................................... 27

10Warranty ............................................................................................................................................................. 28

1 Please Observe the Following

1.1 Emphasized Sections

Warning!

Refers to safety regulations and requires safety measures that protect the operator or

other persons from injury or danger to life.

Caution!

Emphasizes what must be done or avoided so that the unit or other property is not

damaged.

Notice:

A notice gives recommendations for better handling of the unit during operation or

adjustment as well as for service activities.

1.2 For Your Safety

For safe and successful operation of the unit, read these instructions completely. If

the instructions are not observed, the manufacturer can assume no responsibility.

Do not expose the connecting cable to heat, oil, or sharp edges.

Make sure the Unit is securely mounted in an operator accessible area.

Use only original equipment replacement parts.

Do not operate the Unit if it has damage.

Always disconnect the power supply before servicing the unit.

Observe general safety regulations for the handling of chemicals such as Bonderite®

products. Observe the manufacturer’s instructions as stated in the Safety Data Sheet.

While under warranty, the unit may be repaired only by an authorized Henkel

service representative.

1.3 Unpacking and Inspection

Carefully unpack the Bonderite® E-CO Level Control and examine the items contained in

the carton. Inspect the unit for any damage that might have occurred in transit. If such

damage has occurred, notify the carrier immediately. Claims for damage must be made

by the consignee to the carrier and should be reported to the manufacturer.

1.4 Items supplied

1.4.1 E-CO Level Control

1.4.2 Equipment Manual, 8905238

1.4.3 Standard & Master Level Control Installation drawing 8907228

1.5 Features

1.5.1 E-CO Level Control MSTR – Master Level Control has air filter/regulator

1.5.2 E-CO Level Control MSTR – Master Level Control has master pressure

switch for 8 to 25 psig.

1.5.3 Air differential flow regulator

1.5.4 differential pressure switch(s)

1.5.5 Circuit Breaker, internal, 5 Ampere

1.5.6 Indicator lamps

2 Description

The Bonderite® E-CO Level Controls are used to maintain liquid levels in operating chemical

tanks. Working on factory air supply, these controls offer a fail-save technique of solution

level control accurate within +/- ¼ inch.

 Each level control can be supplied in multi-point configurations for customized

applications.

 The system is not affected by agitation in the tanks or by corrosive action of the

contents. No ball floats, needle valves or hazardous electrodes are utilized. Only

the chemically resistant air probe is in direct contact with the process solution.

 Batch operation may be accomplished by utilizing the “High-Low” option. A

measured amount of liquid may be added, and chemical additions and/or agitation

then provided. After chemical reaction, the vessel may then be emptied and the

process repeated.

 Automatic tank heater and pump protection may also be controlled by the “High-

Low” option.

Common Uses:

o Water Tank Level

o Liquid Process Tank Level

o E-Coat Paint Tank Level

o Dilution of Liquids by Volume

o Sump Pump Operation

o Emergency Low Level Alarm

o Chemical Bulk Tank and Day Tank

o Dirty Screen Alarm

Benefits:

o Provides reliable, accurate, simple and safe liquid level control.

o Eliminates Operator errors that result in dangerous and costly low levels or

unnecessary overflows that often result in lost production.

o Assures an adequate and consistent concentration of operating chemicals

when used as part of a Henkel Automatic Process Control System, aiding in

uniform quality of coating and treatment.

o Saves in unnecessary use of water and excess manpower usage to perform

the consistent checking and adjusting of solution levels.

The level is maintained by detecting slight variations in air pressure due to changes in the

liquid level surrounding an immersed air probe. Immersion depth is typically a minimum

of 6” vertical immersion into the process solution. A properly mounted level control is

affected little by wave motion and maintains liquid levels within ¼” at a depth of 1.5 to 5

inches. It is operated by purging a low volume of air (≈ 0.8 cu ft/hr). Clean plant air range

of 30 to 150 psi must be supplied to the master pressure regulator of the system. A low air

pressure switch, filter regulator, pressure regulator and gauge are incorporated into the

master level control assembly. Each master assembly includes a circuit breaker, master

pressure switch, and at least one point of level control. A shutdown or loss of sufficient

plant air will cause an automatic shutdown of the Henkel Level Control System electrical

circuit. The loss of plant air may easily be alarmed by a warning signal which can be

supplied as an option.

The electrical and pneumatic components are housed in an enclosure. Each level control

uses at least one flow control to limit the air volume used and a micro switch to sense the

set-point and operate the load circuits.

3 Technical Data

3.1 Utilities

Operating voltage : 110…120 VAC 50/60 Hz

Air Supply to Master : 30…150 psig, clean shop air

Air Flow Regulation : 0.9…2.1 SCFH

3.2 E-CO Level Control Unit Overall & Mounting Dimensions

Level Control Part Number Overall

W x H x D

Mounting

W x H Mounting Hole

E-CO Level MSTR 1 PT 2251341 11.7 x 14.8 x 7.0 6.5 x 10.75 0.31 x 0.94 slot

E-CO Level STD 1 PT 2250048 9.1 x 14.8 x 7.0 6.5 x 10.75 0.31 x 0.94 slot

E-CO Level MSTR 2 PT 2251340 13.6 x 16.8 x 7.0 8.5 x 12.75 0.31 x 0.94 slot

E-CO Level STD 2 PT 2251339 9.1 x 14.8 x 7.0 6.5 x 10.75 0.31 x 0.94 slot

Master Level Control 3 PT 8907225 17.5 x 20.8 x 7.0 12.5 x 16.75 0.31 x 0.94 slot

Standard Level Control 3 PT 8907224 15.1 x 20.8 x 7.0 12.5 x 16.75 0.31 x 0.94 slot

Master level Control 4 PT 8907227 17.5 x 20.8 x 7.0 12.5 x 16.75 0.31 x 0.94 slot

Standard level Control 4 PT 8907226 15.1 x 20.8 x 7.0 12.5 x 16.75 0.31 x 0.94 slot

3.3 General Arrangement

Depicted is a four-point master level control

unit to show the general arrangement of the

level control system features. Configurations

and numbers of components will vary based

on level controller model.

1. Indicator lights (lined up vertically)

2. Master Pressure Regulator (Master Level

Controllers ONLY)

3. Flow Regulator

4. Differential Pressure Switch

5. Master Pressure Switch (Master Level

Controllers ONLY)

6. Circuit Breaker & Electrical Terminal Blocks

4 Installation

Before using the equipment for the first time check it carefully for signs of external

damage. If any shipping damage is found DO NOT USE THE EQUIPMENT – return it to your

supplier immediately.

A simple Henkel Level Control System would consist of a Master Level Control Assembly

(required) on the first process tank, with each subsequent tank utilizing a Standard Level

Control Assembly. Each tank would require its own individual normally closed water

solenoid valve.

With the use of multiple standard level control units; the master level control should

be centrally located between standard units to minimize regulated supply air tubing

length.

Installation of the level control system should be arranged by the purchaser and generally

involves the following:

1. Mount the level control assembly.

2. Plumb the solenoid valve (available from Henkel Corporation) to desired water

supply line.

3. Install the immersion air probe, typically 1” pipe (supplied by others).

4. Install plant air shut-off valve and connect plant air to the Master Level Control.

5. Install ¼” tubing, (supplied by others) from Master Control Regulator to all other

Standard Level Controllers.

6. Install ¼” tubing (supplied by others) to all immersion probes.

7. Connect 120 VAC power to the Master Level Control and to downstream Standard

Level Controllers.

8. Electrically connect the solenoid valve(s) to respective level controllers.

Refer to the installation drawing at the end of section 10 of this manual for further

installation details of the Level Control system.

Use with Henkel Automatic Process Control Systems.

If the Master Level Controller is being used in conjunction with a Henkel Automatic

Control System, the power to the Master and Standard Level Controllers may be

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