SOR 681 Point Level Control Instruction manual

Form 924 (05.18) ©SOR Inc

1/16

The 681 Point Level Control utilizes DPDT relays to provide switching

for peripheral devices (such as pumps) in level applications. A sensor

attached to the control acts as an antenna to transmit the process

material level to the electronics.

The failsafe switch allows the user to determine the relay state when

the process contacts the probe.

The 681 Point Level Control can be mounted with the sensor in the

process (integral units K housing), or up to 150’ (45m) from the

sensor in the remote configuration (R housing).

The 681 Point Level Control constantly monitors sensor integrity. In the

unlikely event of a sensor failure, a secondary relay provides alarm switching.

An optional adjustable differential circuit (AD accessory) allows the user

to select on and off level points for the control. (All adjustments will be

present, but only those corresponding to the accessory in the model

number will function.)

RF Point Level Control

with Sensor Monitor

General Instructions

Registered Quality System to ISO 9001

Design and

specifications are

subject to change

without notice.

For latest revision, go to

www.sorinc.com

NOTE: If you suspect that a product is defective, contact the factory or the

SOR

Representative in your area for a return authorization number (RMA).

This product should only be installed by trained and competent personnel.

Table of Contents

Specications ...................................2

Pre-Installation Test............................3

Installation.......................................4

Remote Cable Connection.....................5

Electrical Connection........................ 6-7

SOR RF Probe Grounding Scheme ...........7

Set Point and Sensor Monitor Calibration ..8

Adjustable Differential Calibration...........9

Sensor Replacement ......................... 10

Troubleshooting ............................... 10

Circuit Board Replacement.................. 11

Varistor Replacement ........................ 11

Fuse Replacement............................ 12

Dimensions ................................ 13-16

2/16

Form 924 (05.18) ©SOR Inc

Specications

Ambient temperature limits ..............................................................................-40 to 160

-40 to 71

Enclosure

Weatherproof.............................................................................................NEMA 4, 4X, IP65

Explosion proof.....................................................................................Class I, Group C & D;

Class II, Group E, F, & G;

Class III; Divisons 1 & 2

Supply voltage ..................................................................................................... See page 8

DPDT relay contact rating .........................................................................10 Amps 250 VAC

10 Amp 30 VDC (resistive)

Remote distance from sensor ............................................................................... 150’/45m

Adjustment range

Range I ...........................................................................................0 - 300pf, .5pF sensitivity

Range II .....................................................................................300 - 1000pf, 1pF sensitivity

Set point stability

Range I .............................................................................................0.075 pF/

F (0.13 pF/

Range II ..............................................................................................0.15 pF/

F (0.27 pF/

Zero rangeablility ......................................................................................................1000pF

Repeatability ................................................................................................................ 0.5%

Adjustable differential range ................................................................................ 0 - 1000pF

Response time .................................................................................................. <100 msec

Power at sensor ............................................................................................... <10 μ joules

Electrostatic discharge (ESD) protection

IEC 1000-4-2 compatible

Electrical conduit connection .............................................................................3/4” NPT(F)

Form 924 (05.18) ©SOR Inc

3/16

Pre-Installation Test



Remove instrument from shipping box and visually inspect for obvious physical dam-

age. Report any shipping damage to the carrier. Report any internal discrepancies to

the factory representative in your area. Record the serial number from the nameplate

should conversation with the factory be necessary.



Remove housing cover.



Place instrument on an insulated surface or support so sensor does not touch a

conductive surface.



Ensure area is safe and observe normal precautions for exposed and powered

electronic components.



Apply appropriate power to terminals of Line Power Terminal Block. (See page 6.)

Move failsafe select switch to LO position and observe green LVL LED. (See ).



Turn the Level adjustment clockwise (25 turns) to decrease the set point until the

green LVL LED turns on.

NOTE: Do not turn the Level adjustment past 25 turns! Damage to the unit could result.



Turn the LEVEL adjustment counterclockwise until the green LED turns off.



Slowly move a hand toward the probe to touch it. The green LED will be on when the

probe is touched. If not, turn the LEVEL adjustment clockwise less than one turn. The

green LED should be on when the probe is touched.



When practical, use a small container of actual process material to calibrate the con-

trol. If the actual process vessel is metal, use a metal container (coffee can, etc.) and

ground it to the instrument housing. If the actual process vessel is an insulator, such

as fiberglass, use a plastic container.



Immerse the sensor in the process material; the LED should light. If not, it may be

necessary to turn the level adjustments.

To detect an interface, such as oil/water or foam/liquid, the lighter material must be

on the sensor, then tuned out. Then move the LEVEL adjustment to detect the heavier

process material. (See and ).

Oil

Water

4/16

Form 924 (05.18) ©SOR Inc

Conduit must be installed between the sensor base and the electronics housing to provide

a raceway for sensor extension cables. (See ).

If the sensor is a solid rod it may be cut or bent for clearance or placement. Use a 3-inch radius

should a bend be required. It is permissible to increase the sensor length by welding a length of

identical rod to the supplied sensor. Re-calibration is required if the probe length is changed.

Installation

Standard Conguration is a 3/4” NPT(M) pipe nipple that threads into a 3/4” NPT(F) vessel

nozzle or half coupling. Allow a 4-inch turn radius. (See and

). Open tanks, vats,

sumps or basins may require a locally-made bracket mount similar to that shown in

Optional Conguration is a raised face or flat face ANSI flange. See Form 1100 for selection.

(See and

Orientation The control can be mounted in any position. Placement and orientation of the

sensor in a vessel is usually determined by available nozzles. The sensor should be away

from fill points to avoid false trips. The insulator bushing on the sensor should protrude

a minimum of 1” from the inner wall of the vessel. The sensor must not touch any metal,

nor should conductive process build-up be allowed to bridge between the sensor and a

grounded metal tank wall.

This product must be installed with an explosion proof breather vent

per Agency requirements and the National Electrical Code-Article 501,

Section F, paragraph 3.

Form 924 (05.18) ©SOR Inc

5/16

Remote Cable Connection

Electical power must be disconnected from explosion proof models before

the cover is removed. Failure to do so could result in severe personal injury

or substantial property damage.

Ensure that wiring conforms to all applicable local and national electrical codes and install

unit(s) according to relevant national and local safety codes.

Fishing the Sensor Extension Cables

One three-conductor extension cable is required. Pull cable from the sensor base so that

the free ends follow the fish through the conduit. (See ).

Connections Inside Sensor Base

Inside the sensor base, a remote circuit

board rests in a plastic holder. Attach the

cable wires to the terminal block on the

circuit board as follows:

Connections Inside Electronics Housing

Inside the electronics housing, unscrew the bracket holding the circuit board in place. Pull

the board out of the holder. At the bottom of the circuit board, there is a connector labeled

“+ - probe”. Attach the cable wires to the terminal block as shown above.

Conduit must be installed between the sensor base and the electronics housing to provide a

raceway for sensor extension cables. (See ).

Terminal Block Cable

+ red wire

- black wire

PROBE white wire

Control Board

Terminal Block

Remote Board

Terminal Block

Conduit must meet Class I Group C & D;

Class ll Groups E, F & G; Division 1 & 2

Electronics Housing

Remote Sensor Board

Probe Connector

Sensor Base

Control Board

6/16

Form 924 (05.18) ©SOR Inc

Electrical Connection

Level and Alarm (See ). DPDT relays: 10 amp 250 VAC; 10 amp 30 VDC (resistive)

Connect external circuit wires as required to screw clamp terminals marked:

C1 (Common) C2 (Common)

NO1 (Normally Open) NO2 (Normally Open)

NC1 (Normally Closed) NC2 (Normally Closed)

Line Power Voltage Limits Max. Current Draw Board Marking

(See ). 12 ± 10% VDC 100 mA + –

24 ± 10% VDC 100 mA + –

120 (95-130) VAC 25 mA L1, N (shown)

240 (195-250) VAC 13 mA L1, L2

Ensure that wiring conforms to all applicable local and national electrical codes and install

unit(s) according to relevant national and local safety codes.

Electrical power must be disconnected from explosion proof models before

the cover is removed. Failure to do so could result in severe personal injury

or substatnial property damage.

1. Remove housing cover.

2. Observe applicable electrical codes and recognized wiring practices.

3. Remove two mounting screws and slide out PC board to expose green

ground screw (Internal Primary Equipment Ground/Earth) in base of housing.

4. Connect green line ground wire to green ground screw on base of housing.

(Ground wire should be a minimum of 18-AWG.)

5. Reposition PC board, replace and tighten mounting screws. Ensure that

banana plug on sensor lead wire is secure in sensor jack.

Connect hot line power wire (typically black) to L1 position on the terminal block.

7. Connect neutral line power wire (typically white) to N position on the

terminal block.

8. Replace cover.

9. Apply power as desired.

1. Perform Steps 1 through 6 above.

2. Connect second hot line power wire (typically red) to L2 position on the

terminal block.

3. Replace cover.

4. Apply power as desired.

1. Perform Steps 1 through 5 above if a case or equipment ground wire is

provided for connection to earth ground.

2. Connect positive line power wire to the terminal marked (+).

3. Connect negative line power wire to the terminal marked (–).

4. Replace cover.

5. Apply power as desired.

120 VAC

(681K7)

240 VAC

(681K8)

12 VDC

(681K5)

24 VDC

(681K6)

Form 924 (05.18) ©SOR Inc

7/16

SOR RF Probe Grounding Scheme

Critical Grounding Path =

Circuit

Board

Line

Neutral

Ground

Electronics

Housing

Power Supply

Line

Neutral

Ground

Process

Connection

SOR Supplied

Stilling Well

(optional)

Probe Center

Conductive Element

IMPORTANT! Do not

provide separate earth

grounding for the process

connection. This can create

a parallel grounding circuit

that will impair operation

and calibration.

Green LVL LED Alarm Relay Terminal Blocks

Failsafe Switch

Level Relay Terminal Blocks

Line Power Terminal Block

Red LED

Yellow LED

Adjustable Differntial Adjustments

(Function only on units

with AD accessory)

Remote Probe Terminal Block

(Remote units only)

Do not provide separate earth grounding

for the process connection. This can

create a parallel grounding circuit

that will impair operation and calibration.

8/16

Form 924 (05.18) ©SOR Inc

Set Point and Sensor Monitor Calibration

The failsafe mode on either rising or falling level can be easily changed in the field. See

procedure and chart below.

NOTE: Upon loss of power, or some component failures, the output relay is de-energized and its

contacts return to the “shelf position” NC (Normally Closed) to signal an alarm condition

regardless of process level.

Sensor Monitor Calibration



Disconnect the probe wire from the circuit.



Turn the SENSOR MONITOR adjustment until the red Sensor Monitor LED just lights.

The circuit will close the normally open contacts on the ALARM relay.



Reconnect the probe wire to the circuit board. The circuit will return the ALARM relay

contacts to the normal state.

Set Point Calibration



Disconnect line power supply.



Remove the housing cover.



Rotate DIFFERENTIAL adjustment 25 turns clockwise, or until you hear the

potentiometer click.



Look at the chart below to determine the correct failsafe switch setting for your application.

Units in Hazardous Locations — Prior to calibration, make sure that the

work area is declassied before removing the explosion proof cover to

calibrate the unit. Failure to do so could result in severe personal injury or

substantial property damage.

Continuity Chart

Fail Safe

NC1 C1 NO1 NO2 C2 NC2

Switch Position Process Level Terminal Continuity

Form 924 (05.18) ©SOR Inc

9/16



Perform set point calibration per instructions.



Locate the DIFFERENTIAL adjustment (See ), and rotate the screw head fully

counterclockwise. Stop when you hear a small click.



Move the process level to the point where the adjustable differential will be set.



Turn the screw head of the DIFFERENTIAL adjustment clockwise until you see the

LEVEL LED change from on to off, or off to on. You will also hear a click as the relay

contacts change state.

Adjustable Differential Calibration (AD accessory)

FAILSAFE LO



Move the process to the level where switching is needed, and move the FAILSAFE

switch to LO.



If the green LVL LED is off, turn the LEVEL adjustment clockwise until the LED just lights.



If the green LED is on, turn the LEVEL adjustment counterclockwise until the LED turns

off. Then turn another 1/4 turn clockwise or until the LED just lights.

FAILSAFE HI



Move the process to the level where switching is needed and move the FAILSAFE

switch to HI.



If the green LED is on, turn the LEVEL adjustment clockwise until the LED just turns off.



If the green LED is off, turn the LEVEL adjustment counterclockwise until the LED

lights. Then turn another 1/4 turn clockwise or until the LED just turns off.

10/16

Sensor Replacement



Disconnect power to the unit.



Remove the housing cover.



Remove two screws holding bracket to plastic holder.



Slide out PC board to expose the sensor connection.



Disconnect the sensor wire.



Unscrew the sensor from the housing.



Apply thread sealant to the male threads of the new sensor.



Thread the new sensor into the bottom of the housing.



Connect the sensor wire to the “probe” connection on the circuit board.



Slide the PC board into the grooves in the plastic ring inside the housing.

Replace the two screws in the circuit board

Reconnect power and replace the housing cover.

Replacement Sensors

See Form 1100 RF Catalog for replacement sensor model numbers

Troubleshooting

Symptom/Problem Possible Cause Corrective Action

No LEDS lit

1. Power supply turned off

2. Improperly wired line power

3. Broken power supply wire

4. Blown fuse

5. Blown varistor

1. Check power supply source

2. check terminal block wiring

3. Check wiring integrity

4. Replace fuse F1

5. Replace varistor VR1, VR2

or VR3

LVL LED remains lit

at all times

1. Probe wire touched housing or

other ground

2. Setpoint is at the lowest level

1. Check probe that probe wire is

properly attached to the probe

2. Turn the LEVEL adjustment

counterclockwise and retry

LVL LED operates

properly, but relay

does not respond

1. Relay contact damage

2. Burned or broken circuits

1. Replace circuit board or relay

2. Replace circuit board

Process material

is not detected

1. Sensitivity is improperly set

2. Highly conductive product

3. Heavy conductive build-up

on the sensor

4. Circuit failure

1. Recalibrate per page 6

instructions

2. Use sheathed sensor

3. Use sheathed sensor and

periodically remove the build-up

4. Replace circuit board

If corrective action is not effective, please consult the factory.

NOTE: Agency certied units, (FM, CSA, IEC) must be returned to SOR for repairs.

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