Rhino® SD3/XD3 Electric Container Level Sensors

Instruction Sheet1615748-02

© 2021 Nordson Corporation 1615748-02

Rhino® SD3/XD3 Electric Container Level Sensors

DescriptionSee Figure 1. The Rhino SD3/XD3 electric container level sensor module uses magnetic sensors to monitor the distance between the bottom of the follower plate and the base surface of the unloader frame. The LVDT (level detect) sensing module consists of a magnet that travels along the length of the LVDT. The placement of the magnet corresponds to the drum level. The controller will display how much material is left based on the LVDT.

The module contains two to four sensors or one LVDT sensing module depending on system configuration:

1. LVDT (Level Detect) Sensing Module (if equipped)

2. Drum Empty Sensor

3. Drum Low Sensor (if equipped)

4. Follower-in-Drum Sensor

5. Ram Top of Stroke Sensor(if equipped)

When a magnet on the frame piston moves in front of the applicable sensor, the sensor sends a signal to the controller.

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355-Gallon Frame

Shown for Reference Only

Figure 1 Container Level Sensors

2 Rhino® SD3/XD3 Electric Container Level Sensors

© 2021 Nordson Corporation1615748-02

InstallationWARNING: � Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation.

CAUTION: � To prevent damage to the equipment, personnel performing these procedures must know how to safely operate the control valve on the Rhino SD3/XD3 unloader.

Magnetic Sensor InstallationTools Required

Flat head screw driver

Magnetic sensor installation consists of installing the magnetic sensors and setting the Drum Empty, Drum Low (if equipped), Follower-in-Drum, and Ram Top of Stroke (if equipped) signal levels.

NOTE: � Read and understand these procedures before installation. If necessary, contact a local Nordson representative for assistance.

See Figure 2.

1. Turn the power off to the unloader.

2. Install the magnetic sensors onto the frame tie rod at the approximate positions shown in Figure 2 using two set screws (9). Ensure the magnetic sensors sit against the frame cylinder.

CAUTION: � To prevent damage to the proximity sensor, do not overtighten the set screws.

NOTE: � These installation steps are dependant on the system configuration. Not all components, parts, or steps, are applicable to all configurations. Configurations with two sensors will have no Y splitter cables, three sensors will have one Y splitter cable, and four sensors will have two Y splitter cables.

3. Connect the magnetic sensors to the Y splitter cables. The Ram Top of Stroke (4) and the Follower-in-Drum (3) sensors connect to the same Y splitter cable (6) and the Drum Low (2) (if equipped) and Drum Empty (1) sensors connect to the same Y splitter cable (7).

4. Connect the Ram Top of Stroke (if equipped)/Follower-in-Drum Y splitter cable (6) to the 0.5 m cable (5) and connect the Drum Low/Drum Empty Y splitter cable (7) to the 1 m cable (8).

5. Connect the two cables (5 and 8) to the control module.

3Rhino® SD3/XD3 Electric Container Level Sensors


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Figure 2 Magnetic Sensor Installation



Set the Low, Empty and Follower-in-Drum Level SignalsRefer to Table 1. The Low and Empty Level signals are factory-set. If desired, adjust the proximity sensor to change the factory settings.

CAUTION: � To prevent damage to the equipment, personnel performing these procedures must know how to safely operate the elevator control valve on the Rhino SD2/SD3 unloader.

Perform the Change the Factory Settings procedure below to change the factory settings. Perform the Reset the Factory Settings procedure to reset the Follower-in-Drum, Low, and Empty Level signals back to the factory settings.

Table 1 Low and Empty Level Signal Factory Settings

Signal Setting

Low

5-Gal Follower Plate: 4.5 in. between the bottom of the follower plate and the frame base plate rails.55-Gal Follower Plate: 7.5 in. between the bottom of the follower plate and the frame base plate rails.

Empty

5-Gal Follower Plate: 1.5 in. between the bottom of the follower plate and the frame base plate rails.55-Gal Follower Plate: 1.5 in. between the bottom of the follower plate and the frame base plate rails.Mini-Tote: 2.375 in. between the bottom tip of the sensor and the cylinder base.

Follower-in-Drum

5-Gal Follower Plate: ≥ 16.5 in. between the bottom of the follower plate and the frame base plate.

NOTE: � The Follower-in-Drum setting must be adjusted in the field due to customer specific drum sizes.55-Gal Follower Plate: ≥ 36.5 in. between the bottom of the follower plate and the frame base plate.

NOTE: � The Follower-in-Drum setting must be adjusted in the field due to customer specific drum sizes.



Change the Factory Settings

NOTE: � The bottom lip on standard containers can vary and must be taken into consideration when making adjustments to the magnetic sensors.

NOTE: � Due to the variation in material containers, adjustment of the Drum Empty sensor by the equipment end user is necessary to achieve minimal material waste.

NOTE: � These steps are dependant on the system configuration. Not all components, parts, or steps are applicable to all configurations.

See Figure 2.

1. Loosen the set screws (9), move the magnetic sensor to the desired position, and tighten the set screws (9).

2. Repeat step 1 for the remaining magnetic sensors if necessary.

3. Use the control valve to and lower the follower plate to test the Follower-in-Drum, Low, and Empty Level signals.

4. Adjust as necessary.



Reset the Factory Settings

NOTE: � Have spacers of proper height on hand before performing this procedure.

NOTE: � These steps are dependant on the system configuration. Not all components, parts, or steps are applicable to all configurations.

See Figure 3-Figure 5.

1. Put power to the sensors.

2. Set spacers on the frame base plate for 55-gallon and 5-gallon configurations only. For mini-tote configurations use the distance between the top of the cylinder and the bottom of the sensor. Use the elevator control valve to lower the follower plate onto the spacers.

3. Loosen the set screws on the magnetic sensor. Starting from the bottom of the frame cylinder, move the sensor up until the sensor is activated. Tighten the set screws to secure the magnetic sensor.

4. Raise the follower plate. Remove the spacers (if used) from the base plate.

5. Repeat steps 1-3 for the remaining magnetic sensors if necessary.

6. Use the control valve to lower the follower plate to test the Follower-in-Drum, Low, and Empty Level signals.


55-Gallon Follower Plate

Empty setting spacer height: 1.5 in.

NOTE: � Spacer on top of base-plate rails.

Low setting spacer height: 7.5 in.

NOTE: � Spacer on top of base-plate rails.

Follower-in-Drum height:

NOTE: � This setting MUST be adjusted in the field to the customer specific container being used.

Figure 3 Factory Setting for 55-Gallon Follower



Empty Setting Spacer Height: 1.5 in. Low Setting Spacer Height: 4.5 in.

Follower-in-Drum height: 16.5 in.

NOTE: � This setting MUST be adjusted in the field to the customer specific container being used.

5-Gallon Follower Plate

Figure 4 Factory Setting for 5-Gallon Follower

Empty setting height: 2.375 in.

NOTE: � From bottom of sensor to top of cylinder base

Mini-Tote Follower Plate

Figure 5 Factory Setting for Mini-Tote Follower



LVDT InstallationTools Required

Flat head screw driverHex key socket setWrenchAdjustable wrenchLoctite® Threadlocker Blue 242®

NOTE: � Read and understand these procedures before installation. If necessary, contact a local Nordson representative for assistance.

See Figure 6.


2. Apply Loctite Threadlocker Blue 242 to the male threads of LVDT rod (4). Install the 5.3 mm ID x 8 mm OD x 3 mm thick spacer (2) onto the LVDT rod (4), hand tighten LVDT rod (4) into captive magnet ball socket (1) and allow the Loctite Threadlocker Blue 242 to cure.

3. Assemble the mounting brackets (25) and two support brackets (23) to the mounting plate (24) with the 12 socket screws (5) and 12 flat washers (6) provided with the mounting brackets (25). Snug all hardware.

4. Assemble the frame bracket (16) to the Rhino frame using two M12 x 1.50 x 35 hex cap screws (14) for SM frames or and two M12 flat washers (15) for SM frames or two M16 x 2.0 x 35 hex cap screws (14) and two M16 flat washers (15) for LG frames.

NOTE: � If the barcode reader kit is installed, assemble LVDT frame bracket first then re-install the barcode reader bracket on top.

5. Assemble the mount bracket (22) and mounting plate (24)/support brackets (22) assembly using two M5 x 0.80 x 10 socket screws (7) and two M5 flat washers (8). Depending on which frame is being used (125 mm or 160 mm) ensure to align and mount plate (24) to the proper hole pattern of mount bracket (item 22).

• Upper hole pattern to be used with 125 mm frame

• Lower hole pattern to be used with 160 mm frame

6. Wrap the worm-drive hose clamps (21); with the worm drive located to the outside of the cylinder frame; around the frame cylinder to sit on top of the support brackets (23) and secure the support brackets (23) to the frame cylinder.

7. Slide the LVDT I/O link (3) into the mounting brackets (25) until the bottom of the LVDT I/O link (3) is 1.5 in. from the base plate of the frame.

8. Adjust LVDT I/O link (3) assembly until it is parallel to the frame cylinder and tighten all hardware. Torque the screws fastening LVDT I/O link (3) assembly to the mounting plate (24) to 17 in-lb.

9. Install cross-over bracket (12) onto the ram cylinder shaft using the two clamp bodies (13 and 20), cover plate (19) and two M6 x 1.0 x 70 socket screws (17) and two M6 flat washers (18).

10. Slide the captive magnet ball socket (1) and LVDT rod (4) assembly onto the LVDT I/O link (3). The arrow on the magnet ball socket (1) must be facing up.

11. Fasten the LVDT rod (4)/captive magnet ball socket (1) assembly to the cross-over bracket (12) using an M5 x 0.8 x 20 socket screw (11), 5.3 mm ID x 8 mm OD x 2 mm thick spacer (9), and M5 lock nut (10).



12. Align LVDT rod (4) parallel to the LVDT I/O link (3) by rotating the cross-over bracket (12) on the ram cylinder shaft. Make sure the cross-over bracket (12) remains in contact with the cross over bar. Tighten the cross-over bracket hardware.

13. Connect the 4-pin micro cable to the top of the LVDT I/O link (3) and connect the other end to the control module.

14. Power on the unloader to return to service.

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125 mm Frame Mounting Holes

Worm Drive Facing Out

1.5 in. Between Base Plate and LVDT I/O Link

160 mm Frame Mounting Holes Captive Magnet

Ball Sensor Arrow UP

Figure 6 LVDT Rod Installation



RepairWARNING: � Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation.

CAUTION: � To prevent damage to the equipment, personnel performing these procedures must know how to safely operate the elevator control valve on the Rhino SD3/XD3 unloader.

Repair consists of replacing the magnetic sensors and setting the Drum Empty, Drum Low, Follower-in-Drum, and Ram Top of Stroke signal levels and/or replacing the LVDT rod and/or LVDT I/O link.

NOTE: � Read and understand these procedures before performing repairs. If necessary, contact a local Nordson representative for assistance.

Replace a Magnetic SensorTools Required

Flat head screw driver

See Figure 7.

1. Turn off the power to the unloader.

2. Disconnect the cables (5) from the magnetic sensors (1).

3. Mark the position of the magnetic sensor (1).

4. Loosen the set screws (4) securing the magnetic sensor (1) to the frame tie rod and rotate the bracket (3) away from the cylinder. Remove the sensor (2) from its mounting bracket (3).

5. Install the new sensor (2) into the mounting bracket (3). Rotate the sensor bracket (3) and sensor (2) until the sensor touches the cylinder wall. Locate magnetic sensor (1) at the marked position and tighten the set screws (4).

CAUTION: � To prevent damage to the proximity sensor, do not overtighten the set screws.

6. Connect the cables (5) to the magnetic sensors (1).


8. Use the control valve to raise and lower the follower plate to test the Drum Empty, Drum Low, Follower-in-Drum, and Ram Top of Stroke signals.




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55-Gallon Frame Shown for Reference Only

Figure 7 Replacing a Magnetic Sensor



Replace the LVDT I/O Link and/or LVDT RodTools Required

Flat head screw driverHex key socket setWrenchAdjustable wrenchLoctite Threadlocker Blue 242

See Figure 8.


2. Disconnect the 4-pin micro cable from the top of the LVDT I/O link (3).

3. Remove the M5 x 0.8 x 20 socket screw (7), 5.3 mm ID x 8 mm OD x 2 mm thick spacer (6), and M5 lock nut (9) securing the LVDT rod (4)/captive magnet ball socket (1) assembly to the cross-over bracket (8).

4. Remove the LVDT rod (4)/captive magnet ball socket (1) assembly, then remove the captive magnet ball socket (1) and 5.3 mm ID x 8 mm OD x 3 mm thick spacer (2) from the LVDT rod (4).

5. Continue with step 6 if replacing the LVDT I/O link (3) or skip to step 9 if only replacing the LVDT rod (4).

6. Loosen the screws (5) securing the LVDT I/O link (3) assembly to the mounting plate (11). Slide the LVDT I/O link (3) out of the mounting brackets (10).

7. Slide the new LVDT I/O link (3) into the mounting brackets (10) until the bottom of the LVDT I/O link (3) is 1.5 in. from the base plate of the frame.

8. Adjust LVDT I/O link (3) assembly until it is parallel to the frame cylinder and tighten all hardware. Torque the screws (5) fastening LVDT I/O link (3) assembly to the mounting plate (11) to 17 in-lb.

9. Apply Loctite Threadlocker Blue 242 to the male threads of LVDT rod (4). Install the 5.3 mm ID x 8 mm OD x 3 mm thick spacer (2) onto the LVDT rod (4), hand tighten LVDT rod (4) into captive magnet ball socket (1) and allow the Loctite Threadlocker Blue 242 to cure.

10. Slide the captive magnet ball socket (1) and LVDT rod (4) assembly onto the LVDT I/O link (3). The arrow on the magnet ball socket (1) must be facing up.

11. Fasten the LVDT rod (4)/captive magnet ball socket (1) assembly to the cross-over bracket (8) using an M5 x 0.8 x 20 socket screw (7), 5.3 mm ID x 8 mm OD x 2 mm thick spacer (6), and M5 lock nut (9).

12. Align LVDT rod (4) parallel to the LVDT I/O link (3) by rotating the cross-over bracket (8) on the ram cylinder shaft. Make sure the cross-over bracket (8) remains in contact with the cross over bar. Tighten the cross-over bracket hardware.

13. Re-connect the 4-pin micro cable to the top of the LVDT I/O link (3).




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Figure 8 Replace the LVDT I/O Link and/or LVDT Rod



PartsTo order parts, call the Nordson Industrial Coating Systems Customer Support Center at (800) 433−9319 or contact your local Nordson representative.

Container Level SensorsSee Figure 9 and refer to the following parts lists.

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1a

1b

1c

1d

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Figure 9 Container Level Sensors



80-100 mm ModulesItem Part Description Quantity Note— - - - - - - MODULE, sensor, empty, 24 V, SD3/XD3, DP frame —— - - - - - - MODULE, sensor, low/empty, 24 V, SD3/XD3, DP frame —1 1617235 • SENSOR, assembly, rhino, cylinder, SD3/XD3, 80/100 mm AR A

1a 1617238 • • SENSOR, cylinder, Rhino SD3/XD3 AR A1b 1617239 • • MOUNT, sensor, cylinder, 80-100 mm AR A1c - - - - - - • • NUT, hex, jam, M3 x 0.5 x 8, steel, zinc, per ISO 4035 AR A1d - - - - - - • • SCREW, set, cone, M3 x 0.5 x 8, steel, zinc, class 12.9, per ISO 4027 AR A2 1615820 • CABLE, 4-pin micro, 0.5 m, male/female AR A3 1615817 • CABLE, Y, 4-pin, 1 male/2 female, 0.3 m AR A4 1615821 • CABLE, 4-pin micro, 1 m, male/female AR A

NOTE: A. Quantity dependant on configuration.

AR: As Required

125 mm ModulesItem Part Description Quantity Note— - - - - - - MODULE, sensor, empty, 24 V, SD3/XD3, SM frame —— - - - - - - MODULE, sensor, low/empty, 24 V, SD3/XD3, SM frame —1 1617236 • SENSOR, switch, magnetic, 24 V, cone set screw AR A

1a 1617238 • • SENSOR, cylinder, Rhino SD3/XD3 AR A1b 1617240 • • MOUNT, sensor, cylinder, 125 mm AR A1c - - - - - - • • NUT, hex, jam, M3 x 0.5 x 8, steel, zinc, per ISO 4035 AR A1d - - - - - - • • SCREW, set, cone, M3 x 0.5 x 8, steel, zinc, class 12.9, per ISO 4027 AR A2 1615820 • CABLE, 4-pin micro, 0.5 m, male/female AR A3 1615817 • CABLE, Y, 4-pin, 1 male/2 female, 0.3 m AR A4 1615821 • CABLE, 4-pin micro, 1 m, male/female AR A


AR: As Required

160-200 mm ModulesItem Part Description Quantity Note— - - - - - - MODULE, sensor, empty, 24 V, SD3/XD3, LG frame —— - - - - - - MODULE, sensor, low/empty, 24 V, SD3/XD3, LG frame —1 1617237 • SENSOR, switch, magnetic, 24 V, cone set screw AR A

1a 1617238 • • SENSOR, cylinder, Rhino SD3/XD3 AR A1b 1617241 • • MOUNT, sensor, cylinder, 160-200 mm AR A1c - - - - - - • • NUT, hex, jam, M3 x 0.5 x 8, steel, zinc, per ISO 4035 AR A1d - - - - - - • • SCREW, set, cone, M3 x 0.5 x 8, steel, zinc, class 12.9, per ISO 4027 AR A2 1615820 • CABLE, 4-pin micro, 0.5 m, male/female AR A3 1615817 • CABLE, Y, 4-pin, 1 male/2 female, 0.3 m AR A4 1615821 • CABLE, 4-pin micro, 1 m, male/female AR A


AR: As Required



LVDT SensorSee Figure 10 and refer to the following parts lists.

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Figure 10 LVDT Sensor



SM Frame ModuleItem Part Description Quantity Note— 1620302 KIT, sensor, LVDT, 24 V, SD3/XD3, SM —1 1618484 • SPACER, aluminum, 5.3 mm ID x 8 mm OD x 3 mm thick 12 1619362 • ROD, LVDT, 1345 mm, M5, 125 mm/160 mm/ welded frame 13 982780 • SCREW, socket, M5 x 0.8 x 10, zinc 44 - - - - - - • WASHER, flat, M, regular, M5, steel, zinc, per ISO 7089 45 324896 • GROMMET, rubber, 0.812 ID x 1.25 OD 16 1617800 • SPACER, aluminum, 5.3 mm ID x 8 mm OD x 2 mm thick 17 276141 • NUT, lock, M5 18 1602557 • SCREW, button, socket, M5 x 0.8 x 20, zinc 19 983410 • WASHER, flat, M, narrow, M6, steel, zinc 2

10 1619405 • SCREW, socket, M6 x 1.0 x 70, zinc 211 345422 • SCREW, hex, cap, M12 x 1.5 x 35, zinc 212 983194 • WASHER, flat, M, regular, M12, steel, zinc 213 - - - - - - • CLAMP, hose, worm-drive, 2.5-5.50, stainless steel 214 1616444 • LVDT, 1100 mm, I/O link, M12 1NS 1615823 • CABLE, 4-pin micro, 3 M, male/female 1NS 939110 • CABLETIE, 3.9 in., 185°F/85°C, nylon, natural 2

LG Frame ModuleItem Part Description Quantity Note— 1620303 KIT, sensor, LVDT, 24 V, SD3/XD3, LG —1 1618484 • SPACER, aluminum, 5.3 mm ID x 8 mm OD x 3 mm thick 12 1619362 • ROD, LVDT, 1345 mm, M5, 125 mm/160 mm/ welded frame 13 982780 • SCREW, socket, M5 x 0.8 x 10, zinc 44 - - - - - - • WASHER, flat, M, regular, M5, steel, zinc, per ISO 7089 45 324896 • GROMMET, rubber, 0.812 ID x 1.25 OD 16 1617800 • SPACER, aluminum, 5.3 mm ID x 8 mm OD x 2 mm thick 17 276141 • NUT, lock, M5 18 1602557 • SCREW, button, socket, M5 x 0.8 x 20, zinc 19 983410 • WASHER, flat, M, narrow, M6, steel, zinc 2

10 1619405 • SCREW, socket, M6 x 1.0 x 70, zinc 211 1607976 • SCREW, hex, cap, M16 x 2.0 x 35, zinc 212 983019 • WASHER, flat, regular, M16, steel, zinc 213 - - - - - - • CLAMP, hose, worm-drive, 4.13-7.00, stainless steel 214 1616444 • LVDT, 1100 mm, I/O link, M12 1NS 1615823 • CABLE, 4-pin micro, 3 M, male/female 1NS 939110 • CABLETIE, 3.9 in., 185°F/85°C, nylon, natural 2



Issued 06/21

Original copyright date 2021. Nordson and the Nordson logo are registered trademarks of Nordson Corporation.

All other trademarks are the property of their respective owners.

SchematicsRefer to the following foldout schematics for the level sensors.

NOTE: � LVDT sensors schematics are based on the system set up and are provided by the application engineer.

NOTE: � Visit Nordson eManuals for a high-resolution view of the wiring diagrams and schematics. Go to http://emanuals.nordson.com for an electronic version of the manual for Rhino SD3/XD3 Level Sensors.

Number Description10018521 Rhino SD3/XD3 Level Sensor Schematics

http://emanuals.nordson.com

Rhino® SD3/XD3 Electric Container Level Sensors

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