Temperature and leakage relay

type ABS CA 462

CA 462 is designed to spy and detect leakage and temperature in
pumps and mixers. The amplifier is housed in a norm enclosure fitted
for DIN-rail mounting. The unit is available in two executions, 24 VDC
or 110-230 VAC supply. To minimize the risk of false alarms the leak-
age failure has to be detected for time duration of approximately 10
seconds. To simplify the mounting the unit is fitted with plug-in type
of connectors.

The unit has separate alarm outputs for temperature and leakage.
CA 462 also has main contactor relay output energized depend-
ing on alarm/s with manual reset option. Included in the kit is also a
Xylem MiniCas adaptor.

Features:
• Leakage monitoring with 10 sec alarm delay
• Temperature monitoring
• Relay output 250 VAC 3 Ampere
• Connection via plug-in connectors
• DIN-rail mounted

Technical specifications
Description Standard
Temperature input threshold (±10%) > 3.3 kohm (PTC / Klixon)
Max PTC current < 0.6 mA
PTC source voltage 12 VDC
Leakage sensor voltage 12 VDC
Max leakage sensor current < 15 µA
Leakage detection threshold (±10%) < 100 kohms
Leakage alarm delay 10 seconds
Ambient operating temperature -20 to +50 ºC (-4 to +122 ºF)
Ambient storage temperature -30 to +80 ºC (-22 to +176 ºF)
Degree of protection IP 20, NEMA: Type 1
Housing material PPO and PC
Mounting DIN Rail 35 mm
Installation category CAT II
Pollution degree 2
Flame rate V0 (E45329)
Humidity 0-95 % RH non-condensing
Dimensions H x W x D: 108 x 70 x 58 mm (4.25 x 2.76 x 2.28 inch)
16907006 110-230 VAC, 50 Hz/60 Hz
Power supply
16907007 18-36 VDC, SELV or Class 2
Fuse Max 10 A
Terminal wire size Use copper (Cu) wire only. 0.2 - 2.5 mm2 flexible core, stripped length 8 mm.
Terminal tightening torque 0.56 - 0.79 Nm (5-7 lbs-in)
Power consumption <5W
Max load alarm relays 250 VAC 3 Ampere resistive load
Altitude Max 2000 MASL or 6562 ft. AMSL
Max load output pump blocking relay 250 VAC 6 Ampere resistive load

Complience
Electrical connection diagram

Output
Pump contactor Temperature
maneuver Alarm Relay
Power Output Leakage
Supply Alarm Relay

PTC or Leakage
Klixon sensors CA 462

CA 462

Bridged if manual
reset is requested
Connect terminal 12
to ground or housing Reset
of the pump switch

Alarm and relay function table

Alarm type Alarm LED Input state Output relay state Remark

Temperature Leakage Temp Leak Pump Alarm Leak

(9 & 10) (11 & 12) (5 & 6) (4 & 3) (2 & 1)

Normal
closed open closed open open
operation

Temperature Yes - > 3.3 kohm open open closed open Pump stops
Leakage - Yes closed < 100 kohm closed open closed Pump runs
Temp. + Leak. Yes Yes > 3.3 kohm < 100 kohm open closed closed Pump stops

Dimensions
130 mm
(5,13)
108 mm
(4,25)

58 mm
(2,28)

60 mm
(2,36)

108 mm
(4,25)

70 mm
(2,76)

www.sulzer.com
CA 462 en (10.2018), Copyright © Sulzer Ltd 2018
This document does not provide a warranty or guarantee of any kind. Please contact us for a description of the warranties and guarantees offered with our products. Directions for
use and safety will be given separately. All information herein is subject to change without notice.
 Temperature and leakage relay type ABS CA 462

CA
CA 462
462
81907004M (04/2022)

EN Installation guide
www.sulzer.com
 Copyright © 2019 Sulzer. All rights reserved.
This manual, as well as the software described in it, is furnished under license and may be used or copied only
in accordance with the terms of such license. The content of this manual is furnished for informational use only,
is subject to change without notice, and should not be construed as a commitment by Sulzer. Sulzer assumes
no responsibility or liability for any errors or inaccuracies that may appear in this book.
Except as permitted by such license, no part of this publication may be reproduced, stored in a retrieval sys-
tem, or transmitted, in any form or by any means, electronic, mechanical, recording, or otherwise, without the
prior written permission of Sulzer.
Sulzer reserves the right to alter specifications due to technical developments.

81907004M

EN
4
 1 FUNCTION AND USAGE

CA 462 is a combined standalone leakage detection and temperature blocking relay for DIN rail mount.

1.1 Function leakage

In case of water leakage, the resistance between the sensor electrode and housing will decrease. If the resist-
ance becomes less than 100 kohm (±10 %) between terminals 11 and 12, the relay contact on terminal 1 and 2
closes. The signal has to be stable for at least 10 seconds before the relay is been activated.

1.2 Function temperature blocking

If the temperature in the pump is rising and the terminal protector sets off, the CA 462 is blocking the pump
without any delay.
Automatic reset
− if terminal 14 and 15 are open; pump starts automatically when the temperature is back to normal.
Manual reset
− if terminal 14 and 15 are bridged; manual reset has to be done by terminal 13 and 14 after the temperature
is back to normal.

Table 1: Connection chart

Terminal Description

1 Leakage alarm relay (NO)

2 Leakage alarm relay
3 High temperature alarm relay (NO)
4 High temperature alarm relay
5 Pump relay (NO) (Closed under normal operation)
6 Pump relay
7 Power supply (0 V or N)
8 Power supply (+24 VDC or L1)
9 Input from pump temperature sensor (PTC / Klixon)
10 Input from pump temperature sensor (PTC / Klixon)
11 Input from pump leakage probes
12 Connect to ground or pump chassis
13 Reset switch for high temperature alarm
14 Reset switch for high temperature alarm
15 Manual reset required if bridged to terminal 14*
* If bridged to terminal 14; manually reset is required after high temperature alarm after condi-
tion is back to normal. If not bridge; pump start automatically when condition is back to normal.

Table 2: Product reference

Article Description

16907006 CA 462 110-230 VAC supply voltage

16907007 CA 462 18-36 VDC supply voltage

One item of Xylem MiniCas adapter is included in both 16907006 and 16907007.
81907004M

EN
5
 Table 3: Logic table of relay

Alarm type Alarm LED Input state Output relay state Remark

Tempera- Leakage Temp Leak Pump Alarm Leak

ture (9 & 10) (11 & 12) (5 & 6) (4 & 3) (2 & 1)

closed open closed open open Normal

operation

Temperature Yes - > 3.3 kohm open open closed open Pump stops
Leakage - Yes closed < 100 kohm closed open closed Pump runs
Temp. + leak. Yes Yes > 3.3 kohm < 100 kohm open closed closed Pump stops

81907004M

EN
6
 2 CONNECTION DIAGRAM

2.1 Electrical connection

If several sensors are to be used from the pump, then they must be connected together.
Leakage: Sensors must be in parallel.
It is very important to have in mind that this practice avoids alarms to be distinguished. Sulzer
highly recommends to use one module per signal to allow not only distinguishing but also acting
in a different way according to the alarm category/severity.
Temperature (Klixon or PTC): Sensors must be in series.

Output
Pump contactor Temperature
maneuver Alarm Relay
Power Output Leakage
Supply Alarm Relay

PTC or Leakage
Klixon sensors CA 462

Bridged if manual
reset is requested
Connect terminal 12
to ground or housing Reset
of the pump switch

Figure 1 Electrical connection diagram

When several CA 462 units are used, the reset buttons cannot be wired together. The solution is to use one
reset button to each unit or an external relay which control all the reset buttons as figure 2.

Reset CA 462 - ...n

Reset CA 462 - 2

Reset CA 462 - 1
Reset all CA 462

External relay

Figure 2 Connection of reset function for multiple CA 462 units

If pump is operated from a motor drive or frequency converter, special precautions are required.
The high electric noise level can distort electrical readings and in extension jeopardize functionality.
81907004M

To avoid conducted electrical noise, follow best practices and manufacturer EMC compliance recommenda-
tions when installing frequency converters. Use shielded cables and 50 cm separation between power and
signal cables. Ensure that the cables are also separated from each other in cabinets.

EN
7
 3 ACCESSORIES

3.1 Xylem MiniCAS adapter

Xylem MiniCAS adapter is included in P/N 16907006 and 16907007.
The MiniCAS adapter can also be ordered as a spare part, P/N 16907009.

3.1.1 Connection diagram MiniCAS adapter

Xylem MiniCAS adapter is a PCB with resistor network for interfacing CA 462 to Xylem MiniCAS relay. The
output to MiniCas is polarity independent.

CA 462

Figure 3 Connection diagram for MiniCAS adapter

Table 4: Logic diagram of output resistance related to the inputs

Temperature input Seal leak input Output resistance

OK OK Nominal (1500 Ω)

OK Seal failure condition LOW (400 Ω)

Over-temperature condition
OK or seal failure condition HIGH (>4000 Ω)
(open or disconnected)

81907004M

EN
8
 4 TECHNICAL DATA

4.1 Technical data CA 462

Temperature input threshold (±10%) > 3.3 kohm (PTC / Klixon)

Max PTC current < 0.6 mA

PTC source voltage 12 VDC

Leakage sensor voltage 12 VDC

Max leakage sensor current < 15 µA

Leakage detection threshold (±10%) < 100 kohm

Leakage alarm delay 10 seconds

Ambient operating temperature –20 to +50 °C (–4 to +122 °F)

Ambient storage temperature –30 to +80 °C (–22 to +176 °F)

Degree of protection IP 20, NEMA: Type1

Housing material PPO and PC

Mounting DIN Rail 35 mm

Installation category CAT II

Pollution degree 2

Flame rate V0 (E45329)

Humidity 0–95% RH non-condensing

Dimensions H x W x D: 108 x 70 x 58 mm
(4.25 x 2.76 x 2.28 inch)

16907006 110-230 VAC, 50 Hz/60 Hz

Power supply
16907007 18-36 VDC SELV or Class 2
Fuse Max 10 A

Terminal wire size Use copper (Cu) wire only. 0.2 - 2.5 mm2
flexible core, stripped length 8 mm.
Terminal tightening torque 0.56 - 0.79 Nm (5 -7 lbs-in)

Power consumption <5W

Max load alarm relays 250 VAC 3 Ampere resistive load

Altitude Max 2000 MASL or 6562 ft. AMSL

Max load output pump blocking relay 250 VAC 6 Ampere resistive load

Compliance

Attention If the unit is used in a manner not described in this document the protection provided by the equipment may be
impaired.
81907004M

EN
9
 4.2 Dimensions

130 mm
(5,13)
108 mm
(4,25)

58 mm
(2,28)

60 mm
(2,36)
70 mm 108 mm
(2,76) (4,25)

4.3 Cleaning
How to clean the unit
Powers off the unit and only outside/front shall be cleaned by using a dry, soft cloth. A good choice would be
the microfiber type of cloth and gently wipe the CA 462 unit on front in order not to scratch the overlay. If the
dry cloth did not completely remove the dirt, do not press harder in an attempt to scrub it off. If necessary,
moisten the cloth by adding a small amount of water with thin solution of mild detergent and try again. Never
use detergent with polish or solvent which can have an impact of the plastic surface.

81907004M

EN
10