Operators instructions CleverLevel switch, LFFS CleverLevel switch, type LFFS is an universal level switch, which can be used for all applications in liquids and solids with a DK-value above 1,5 Safety instructions This instrument is constructed and tested according to the current EUdirectives and packed in technically safe condition. In order to maintain this condition and to ensure safe operation, the user must follow the instructions and warnings given in this instruction. During the installation local standards have to be observed. Ignoring the warnings may lead to severe personal injury or substantial damage to property. The product must be operated by trained staff. Correct and safe operation of this equipment is dependent on proper transport, storage, installation and operation. All electrical wiring must conform to local standards and the connection must be made according to the connecting diagrams. Before switching on the power supply take care that other equipment is not affected. Ensure that the supply voltage and the conditions in the environment comply with the specification of the device. Before switching off the supply voltage check the possible effects on other equipment and the processing system. To obtain the specified protection degree, the LFFS must be mounted with a compliant cable. Description The Level Switch LFFS designed to detect levels in tanks, media separation and provide empty-pipe detection or dry-run protection for pumps. A high frequency sweep signal is radiated from the sensor tip into the tank. The media will act as a virtual capacitor, which together with a coil in the sensor head, will form a circuit creating the switch point signal. This virtual capacity will depend of the di-electric value (DK-value) of the media. The Flex-software also features an adjustment facility making the user able to adjust the sensor to a specific media. The Level Switch LFFS measures liquids such as water and beer as well as viscous, sticky fluids, such as honey, yoghurt, toothpaste and ketchup. Even dry medias can be measured, e.g. sugar or flour. The Level Switch LFFS is resistant against CIP and SIP agents. Hygienic installation is also possible with the comprehensive range of accessories, see the overview at page 6. WARNING When the top cover is removed, do not look directly at the blue LED with unshielded eyes or damage to retina may occur ! This product contains no replaceable parts. In case of malfunction the product must be shipped to Baumer for repair. www.baumer.com Operators instructions: 11109132 02 EN Page 1 / 12 2013-08-23 The measurement is precise and unaffected by the mounting position in the tank. In the Flex-software a compensation for foam, bubbles and condensate as well as viscous media can be set. Design and specifications subject to change without notice By means of the FlexProgrammer 9701 the output can be configured to either NPN, PNP or digital output signal. A damping of the output signal can be activated in case of a fluctuating media level, e.g. during tank filling. Operators instructions CleverLevel switch, LFFS Measuring principle The capacity (C) of the media is directly proportional to the dielectric value of the media. A frequency between 100 and 180MHz is swept into the media. When the coil (L) and the capacitor (C) reach a resonance frequency, it will be detected by the electrical circuit. Dimensions G½ hygienic 3A DN38 hygienic G½ hygienic sliding connection 19,0 Safety wire 31,5 100 Sliding connection or 14,5 250 G½ 2 × PEEK sealing washers Spare part set: 4401.8001 Mounting Please refer to “Accessories” data sheet. The welding part has an engraved mark or a leak hole. When the product has been mounted and correctly tightened the gland or M12 plug will align with this mark. Mounting instructions for sliding connection: Make sure that the gland/plug is pointing downwards to prevent fluids from penetrating into the instrument. 3) Tighten the G1/2 Hygienic sliding nipple at 25...30 Nm. Use only the authorised special designed accessories. The product warranty is void when installed with other adapters. Do not use PTFE, fibre or other gaskets. The PEEK tip against the stainless steel welding part will perform a hygienic tightening provided that the guidelines have been followed. Due to the measuring principle it is essential that the sensor tip can “see” an ample amount of the metal shaft or welding part. www.baumer.com 1) Clean the sliding shaft. 2) Mount the smallest ring against the media as indicated. 4) Replace the Washer ring kit when one or both parts are permanently deformed or stick to the shaft of the sliding connection. WARNING The Level Switch LFFS with sliding connection can be mounted in installations with a static pressure up to 16 bar. To prevent personal injuries or property damage it is essential that the safety wire is mounted correctly and is undamaged. Operators instructions: 11109132 02 EN Page 2 / 12 Operators instructions CleverLevel switch, LFFS Mounting Installation of 3A approved and EHEDG certified products: Tighten the union with a torque of: Std. version 20...25 Nm. Sliding connection 25...30 Nm. 1) Use only a 3A approved counter part. 2) The inspection hole should be visible and drained. 3) Mount the instrument in a self drained position. 4) Level the inner surface of the pipe with the counter part. 5) Welding's should be grinded to Ra= 0.8 WARNING Example with PM023 Cannot be drained Fitted incorrect Example with 8126-928 Example with 8126-916 After installation and configuration Check the leak tightness of the sleeve. Check the tightness of glands or M12 plugs. Check the tightness of the cover www.baumer.com Leakage indication hole must be places downwards Operators instructions: 11109132 02 EN Page 3 / 12 Operators instructions CleverLevel switch, LFFS Mounting connections ISO2852 DN38: CAM023.505 DN51: CAM023.640 Variline, type N VAM023 SMS 1145 DN51: SAM020.051.1 Welding for tank PM023 DIN 11851 DN25: MAM020.025 DN40: MAM020.040 DN50: MAM020.050 Welding for tank PM021 Welding for tank 8126916 Welding for pipe end 8126928 Adapter G½ → G1 RAM020.1 Adapter 1” level switch LAM020.3 Adapter, industrial G½ → G1 RAM020.2 Welding to pipe end DN25...50: PM022.1 DN65...100: PM022.2 Welding Ø35 for tank/tube PM025 On a welding adapter there is an arrow or a 3A logo. This must be placed upwards when welding the adapter into a tank (horizontal position). This assures that the electrical connection will be pointing downwards (opposite of the arrow; 3A logo) Refer to data sheet ”Accessories Universal” for further information NOTE: The LFFS must be mounted in a Baumer mounting connection. If not, Baumer do not guarantee correct function or tightness. www.baumer.com Operators instructions: 11109132 02 EN Page 4 / 12 Operators instructions CleverLevel switch, LFFS Media temperature and external length for sliding connection LFFS-xx1.x / LFFS-xx2.x LFFS-xx3.x and LFFS-xx4.x Media temperature °C Media temperature °C 120 115 110 105 100 See example 95 90 85 80 75 50 55 60 65 70 75 80 85 90 Ambient temperature °C For CIP/SIP Media temperature, max. Ambient temperature, max. Duration, max. External length of sliding connection 140°C 60°C 1 hour External length It is essential that the max. ambience temperature for the electronics is never exceeded (85°C). For ATEX approved products please refer ATEX data. Example, how to read External length curve: Example: Media temperature / Ambient temperature / External length 160°C 60°C 120 mm The drawing shows how the sliding connection can be used for at least 4 applications: 1) Mounted at the top of a tank to adjust to a maximum level. 2) Serving as a cooling neck in high media temperature applications. 3) Adjusted to place the sensor tip deeper inside the tank. 4) To reach in through insulation material. A 250 mm sliding connection is mounted in a tank with a total insert length of 130 mm. Hence the external length of the sliding connection will be 250 – 130 = 120 mm. The media temperature will be max. 160 °C. Read the x-axis at 120 mm an the y-axis at 160°C and find that the ambient temperature must be kept below 60°C. In case the radiated heat from the tank will cause a higher ambient temperature at the housing efficient insulation of the tank must be established. When re-ordering a CleverLevel switch If a new CleverLevel switch is installed in an existing application, it is normally a “plug-n’-play” operation. If the settings of the level switch was changed from standard factory settings, it is necessary to re-adjust the new switch to same as the “old” switch. It is possible to save the settings of the “old” switch on the PC and download those again to the new level switch. The factory setting of the sensitivity of the media may vary up to ±5%. This means that if an very exact set point is required, a new teach-in or adjustment by the FlexProgram must be performed. www.baumer.com Operators instructions: 11109132 02 EN Page 5 / 12 Operators instructions CleverLevel switch, LFFS Teach-In using the FlexProgram and FlexProgrammer 9701 Sophisticated settings for Teach-In as well as output type, diagnostics, data logging, tag no. and damping can be configured using the FlexProgrammer 9701. Integrated HELP-menus will give full instruction. Using the FlexProgrammer 9701 alone and Teach-In FlexProgrammer 9701 stand alone menu Press or to browse the menus to access current menu point to return to previous menu and simultaneously to reset FlexProgrammer and go in sleep mode Press Turn on FlexProgrammer if in sleep mode Empty configuration Search for product LFFS/LBFS configuration Product LFFS / LBFS TAG number xxxxxxxxxxxxxxx Range min. x.x% Range max. xx.x% Damping x,x sec Output config. Xxxxxxx Trigger level xx,x% Range hyst. x,xx% Trigger hyst. x.xx% Teach-In Press and simultaneously Select Menu “Teach-In” Search for product = Product LFS/LBFS At empty tank setting 0% At full tank setting 100% Manually Teach-In Make sure that power is on before Teach-In. For best Teach-In it is important the product is fixed in the final application. During Teach-In mode the light intensity of the LED will decrease, please protect your eyes. Step To do LED 1 Connect terminal ”Teach-In” to - VDC (T1 or T2) for 3,5 second Flash 1 time per second 2 With no media present connect ”Teach-In” to - VDC shortly Light on for 2 second and then flash 3 With media present connect ”Teach-In” to - VDC shortly Light on for 2 seconds Result Ready for Teach-in Register ”empty” state. Pls. See note Register ”full” state, stores the value and returns to Normal operation with new setting NOTE: If the media is sticky, foamy, powdery or in other ways leaving parts of the media at the sensor tip this situation has to be established also during the Teach-In process. Otherwise a faulty calibration can be the result. If Teach-In for some reason do not succeed, the CleverLevel Switch LFFS will enter “Error State” and automatically reload factory settings . The factory settings can always be reloaded by connecting the terminal “Teach-In” to -VDC for more than 6.5 seconds. A reloaded factory settings will be confirmed by pulsing light intensity 3 times. Error state description LED Error state www.baumer.com Result Blinking, 3 × short and 1 × long Can normally be fixed by powering off and on and remake the Teach-In. Alternatively remake the Teach-In configuration by use of the FlexProgram and the FlexProgrammer 9701 Operators instructions: 11109132 02 EN Page 6 / 12 Operators instructions CleverLevel switch, LFFS Electrical connection M12 plug: 1 2 3 4 Brown White* Blue Black * To avoid unintended Teach-In, be aware not to connect the Teach-In pin or expose it to any electrical noise during normal operation. Electrical specifications: Power supply 12,5...36 VDC, 35 mA max. Output PNP, NPN or Digital Max. 50 mA, short-circuit and high temperature protected Active “Low” NPN and Digital output (-VDC +2,5V) ±0,5V, Rload 1 kΩ Active “High” PNP and Digital output (+VDC -2,5V) ±0,5V, Rload 1 kΩ Normally open - NO 5 5 1 2 2 5 1 1 2 Normally closed - NC 5 5 2 www.baumer.com 1 2 5 1 2 1 Operators instructions: 11109132 02 EN Page 7 / 12 Operators instructions CleverLevel switch, LFFS ATEX Conditions for Ex certification Connection type Ambient temperature Media temperature Note (max. allowed) G½ hygienic -40 … +85 °C +85 °C 3A DN38 -40 … +60 °C +95 °C 1) -40 … +40 °C +115 °C 1) 100 mm -40 … +85 °C +85 °C Sliding connection -40 … +60 °C +155 °C 1) -40 … +40 °C +175 °C 1) 250 mm -40 … +85 °C +85 °C Sliding connection -40 … +60 °C +195 °C 1) -40 … +40 °C +200 °C 1) 1) Provided that the sensor tip at the instrument is the only part in contact with the media ATEX Gas ia Ex ia IIC T5, ATEX II 1G - Installation A Level Switch LFFS-1xx.x is Ex ia IIC T5, ATEX II 1G approved for application in hazardous areas in accordance with the current EU directives. The product must be installed in accordance with prevailing guidelines for zone 0 with a barrier LFFS-1xx.x with NPN output Note: For NPN output only! A standard barrier may be used NPN out Supply range Temperature class Internal inductivity Internal capacity 24...30 VDC T1...T5 Pls. see above table Li <10 µH Ci <33 nF Barrier data U I P Standard barrier Ex-data <30 VDC <0.1 A <0.75 W Two-channel ZENER barrier Note: There is an electrical connection between intrinsic safe circuit and housing due to the measurement principle Note: LFFS-1xx.x with PNP output For PNP output the barrier module PFOFSI3-B25100-ALG-LS is required for functional purposes. PFOFSI3-B25100-ALG-LS Safe area www.baumer.com + 22...120 VDC or - 90...253 VAC Operators instructions: 11109132 02 EN Page 8 / 12 Operators instructions CleverLevel switch, LFFS ATEX Dust tD A Level Switch LFFS-2xx.x is Ex tD A20 IP67 T100°C, ATEX II 1D approved for application in hazardous areas in accordance with the current EU-directives. The product must be installed in accordance with prevailing guidelines for zone 20 without a barrier. 5 1 2 Ex-data Supply range Load Temperature class VDC I T1...T5 12,5...30 <0.1 A Pls. see table top page 8 12,5...30 VDC ATEX Gas nA A Level Switch LFFS-3xx.x is Ex nA II T5, ATEX II 3G approved for application in hazardous areas in accordance with the current EU directives. The product must be installed in accordance with prevailing guidelines for zone 2 without a barrier. 5 2 Ex-data Supply range Load Temperature class VDC I T1...T5 1 12,5...30 <0.1 A Pls. see table top page 8 12,5...30 VDC Ex-Configuring The FlexProgrammer 9701 configuring unit must not be connected to the CleverLevel Switch LFFS within the hazardous area. Configuring procedure: a) Disconnect mains from the 4...20 mA loop circuit. b) Disconnect the Level Switch from the circuitry within the hazardous area. c) Uninstall and bring the Level Switch to the safe area. d) Connect the FlexProgrammer 9701 and perform the configuring session. e) Re-install the Level Switch in the hazardous area. f) Connect the power supply to the circuit. Outside hazardous area Links Operation instructions in other languages and certificates can be found on Baumer home page Operation instructions Certificates ATEX / DNV WHG certificate/instruction leakage WHG certificate/instruction overfill www.baumer.com www.baumer.com → downloads → certificates-approvals → product main group www.baumer.com → downloads → certificates-approvals → certificate / approval www.baumer.com/LxFS-WHG-Leak www.baumer.com/LxFS-WHG-Overfill Operators instructions: 11109132 02 EN Page 9 / 12 Operators instructions CleverLevel switch, LFFS WHG leakage approval www.baumer.com Operators instructions: 11109132 02 EN Page 10 / 12 Operators instructions CleverLevel switch, LFFS WHG overfill protection approval www.baumer.com Operators instructions: 11109132 02 EN Page 11 / 12 Operators instructions CleverLevel switch, LFFS WHG leakage and overfill protection approval www.baumer.com Operators instructions: 11109132 02 EN Page 12 / 12