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Design & Integration

Warrick Series 16: Direct Mode Bench Test

What is a Series 16 Conductivity Relay in Direct Mode?

The Series 16 conductivity relay measures liquid levels or flow based on the natural conductive properties of the liquid. In Direct mode, the relay energizes when the probe terminals detect liquid conductivity. It can also work with dry contact switches, such as the LS-800 float level switch, for testing or alternative sensor applications.

Purpose of bench testing:

To verify relay operation, wiring, and LED status without installing the relay in
a tank or system.

How do I bench test a Series 16 relay for a high-level alarm?

Short Answer:

Place a jumper between the High (H) and Reference (G) terminals to simulate
liquid presence at the high probe. The relay should energize (LED on), closing
the Normally Open (NO) contact.

Step-by-step procedure:

  1. Place a jumper wire between H and G terminals.
Bench Test Step 1

2. Verify the relay energizes (LED illuminates).

3. Confirm continuity between NO and Common (C) contacts.

4. Remove the jumper between H and G.

Bench Test Step 2

5. Verify the relay de-energizes (LED off).

6. Confirm continuity between Normally Closed (NC) and Common (C) contacts.

How do I bench test a Series 16 relay for a low-level alarm?

Short Answer:

For a low-level alarm in Direct mode, place a jumper between H and G to
simulate liquid at the high probe. Use the NC contact to monitor alarm state.

Step-by-step procedure:

  1. Place
    a jumper between H and G.
Bench Test Step 3
  • 2. Verify relay energizes (LED on)

    • 3. Observe that the NC contact remains open, as it is used for a low-level alarm.

    4. Remove the jumper between H and G.

    Bench Test Step 4

    5. Verify relay de-energizes (LED off)

    6. Confirm continuity between NC and C contacts.

    Note: Low-level alarms typically use Inverse mode, but Direct mode can be tested for verification purposes.

    How do I bench test a Series 16 relay for differential level control (pump or valve)?

    Short Answer:

    Simulate liquid presence at both High (H) and Low (L) probes using jumpers, then remove jumpers sequentially to emulate changing liquid levels.

    Step-by-step procedure:

    1. Place jumpers between H and G and L and G.
    Bench Test Step 5

    2. Verify the relay energizes (LED on), and continuity exists between C and NO.

    3. Remove the jumper between H and G, leaving L and G connected.

    • Relay should remain energized due to latching.
    • Continuity should remain between C and NO.
    Bench Test Step 6

    4. Remove the jumper between L and G.

    • Relay should now de-energize (LED off).
    • NO contact opens, NC contact closes.

    Bench Test Step 7

    What additional tests can I perform on Series 16 relay?

    Short Answer:

    Bench test the relay at the probe fitting or in a bucket of water to confirm
    proper wiring, actuation, and conductivity-based operation.

    Additional Test Options:

    • Test at the probe fitting to ensure wiring integrity and no shorts.
    • Use a bucket of water to simulate liquid presence:
      • Place the H and G probes (or probe wires) in water to simulate liquid
        detection.
    • Observe LED behavior and confirm NO/NC contact states match the expected
      operation.
    • Ensure jumpers are removed when simulating dry conditions.
    • Having a helper observe relay actuation can improve test accuracy.

    Tip: The bucket test verifies the relay’s ability to conduct through the liquid
    itself, not just via jumpers.

    Frequently Asked Questions:

    Q1: Why doesn’t the LED turn on during a bench test?
    A1: Ensure the jumper is placed correctly between the appropriate terminals (H
    and G for high-level alarm). Verify wiring integrity and check that no jumpers
    are loose or shorted.

    Q2: Can I test the Series 16 relay using a float switch instead of conductivity probes?
    A2: Yes, dry contact switches such as the LS-800 can be used in place of probes
    for bench testing purposes.

    Q3: How can I verify the relay wiring without installing it in a tank?
    A3: Perform a bench test using jumpers between the relay terminals and,
    optionally, simulate liquid using a bucket of water at the probe connections.

    Q4: Does the bench test check the relay’s ability to sense liquid conductivity?
    A4: Only partially. Jumpers verify relay actuation and wiring. Testing with
    liquid ensures the relay can conduct through a liquid medium as expected.