PKP FS10 Magnetic Float Level Switch Instruction Manual

PKP FS10 Magnetic Float Level Switch

Safety Information

General Instructions

To ensure safe operation, the device should only be operated according to the specifications in the instruction manual. The requisite Health & Safety regulations for a given application must also be observed. This statement also applies to the use of accessories.
Every person who is commissioned with the initiation or operation of this device must have read and understood the operating instructions and in particular the safety instructions!  The work safety instructions in this manual as well as the safety, accident prevention and environmental protection regulations generally valid for the work area must be observed.

The liability of the manufacturer expires in the event of damage due to improper use, nonobservance of this operating manual, use of insufficiently qualified personnel and unauthorized modification of the device.

Proper Usage

The Level switches FS10 and FS11 are designed to control the level in vessels of liquids which do not attack the device materials. All other usage is regarded as being improper and outside the scope of the device.

In particular, applications in which shock loads occur (for example, pulsed operation) should be discussed and checked in advance with our technical staff.

The series FS10 and FS11 should not be deployed as the sole agents to prevent dangerous conditions occurring in plant or machinery. Machinery and plant need to be designed in such a manner that faulty conditions and malfunctions do not arise that could pose a safety risk for operators.

Dangerous substances

For dangerous media such as e.g. Oxygen, Acetylene, flammable or toxic substances as well as refrigeration systems, compressors, etc. must comply with the relevant regulations beyond the general rules.

Qualified Personnel

The FS10 and FS11 devices may only be installed by trained, qualified personnel who are able to mount the devices correctly. Qualified personnel are persons, who are familiar with assembling, installation, placing in service and operating these devices and who are suitably trained and qualified.

Inward Monitoring

Please check directly after delivery the device for any transport damages and deficiencies. Additional with reference to the accompanying delivery note the number of parts must be checked.
Claims for replacement or goods which relate to transport damage can only be considered valid if the delivery company is notified without delay.

Design and Function

Functional description:
Magnetic float switches work on the float principle with magnetic transmission. A reed contact integrated in the guide tube is actuated through the magnetic field of a ④ permanent magnet, when a preset switch point is reached. The permanent magnet is located within a float , which changes its height with the level of the medium it is ⑥ monitoring.
The switching status of the reed contact can be evaluated and processed by a connected control device.
The number and arrangement of floats is dependent on the number of the defined switch points, their contact function and also the distance between the switch points.

1. Connection housing
2. Cable bushing
3. Mounting thread
4. Guide tube
5. Float stop
6. Float

Safety

• The liquids must not have any large contamination or coarse particulates and must not have a tendency to crystallise. Ensure that the wetted materials of the magnetic float switch are sufficiently resistant to the medium being monitored. Not suitable for dispersions, abrasive liquids, highly viscous media and colours.
• This instrument is not permitted to be used in hazardous areas! Excluded are magnetic float switches which are marked as simple electrical equipment per EN 60079-11.
• The operating conditions specified in the operating instructions must be observed.
• Do not operate the instrument in the direct vicinity of ferromagnetic environments (min. distance 50 mm).
• Do not operate the instrument in the immediate vicinity of strong electromagnetic fields or in the immediate vicinity of equipment that can be affected by magnetic fields (min. clearance 1 m).
• The magnetic float switches must not be exposed to heavy mechanical strain (impact, bending, vibration).
• The technical specifications contained in these operating instructions must be observed. Improper handling or operation of the instrument outside of its technical specifications requires the instrument to be taken out of service immediately and inspected by an authorised PKP service engineer.

Danger:
Work on vessels involves the danger of intoxication and suffocation. No work is allowed to be carried out unless by taking suitable personal protective measures (e.g. respiratory protection apparatus, protective outfit etc.).

Mounting

• Observe all instructions given on the shipment packaging for removing the transportation safety devices.
• Remove the magnetic float switch carefully from the packaging!
• When unpacking, check all components for any external damage.

Mounting preparation:

Functional check:
Before mounting, the float switch can be connected as described in chapter 5.3 and the switch points can be operated manually.

Ensure that the functional check does not start any unintended processes.

Mounting:

• Observe the torque values of screws specified in pipefitting work.

• In the selection of the mounting material (sealings, screws, washers and nuts), take the process conditions into account. The suitability of the sealing must be specified with regard to the medium and its vapours. In addition, ensure it has corresponding corrosion resistance.

• Mount the magnetic float switch either via mounting thread or mounting ③ flange (not illustrated).

• The guide tube should not be ④ inclined more than a maximum of 30° to the vertical.

• If the geometry of the float does not fit through the process connection, the float must be removed before mounting. – For this, before removal,
  mark the position of the float stops ⑤ with a waterproof pen – Mark the mounting position of the floats (e.g. “Up”) – After the magnetic float switch has been mounted, the float should be re-attached within the inside of the tank (pay attention to the mounting position!). – Float stops must then be re- attached at ⑤ the marked points.

• The number of floats and also the position of the float stops are dependent upon the dimension and the number of switch points.

Electrical Connection

• The electrical connection must only be made by qualified skilled personnel.
• Connection details and switching functions are given on the connection diagram on the instrument and the connection terminals are appropriately marked (exception: Versions with only one normally closed or normally open contact).
• Seal the cable bushing ② at the connection housing . ①
• The mains connection lines to be provided must be dimensioned for maximum instrument current supply and comply with IEC 227 or IEC 245.

Warning:

Electrical connection errors of the magnetic float switches can destroy the reed contacts.
This can lead to a malfunction in the plant and thus lead to injury to personnel or damage to equipment.
▶▶ No direct operation in circuits with inductive loads.
▶▶ No direct operation in circuits with capacitive loads, e.g. PLC, PCS or cable lengths > 50 m.
▶▶ Do not exceed the permissible switching power.

Connection with inductive load:

With inductive loads, the magnetic float switches should be protected by connection to an RC element or a free-wheeling diode.

Connection with capacitive load:

Attention:
To increase the service life of the contacts, we recommend operation with a contact protection relay.

Connection diagrams:
Colour coding per IEC 757

Abbreviations, definitions:
L-SP: Level switch point
T-SP: Temperature switch point
NO/NC: Normally open / normally closed
CO: Change-over

Connector pin assignment:

Switching capacity:

exact switching capacity: see device sticker!

Permissible switching capacity

Exact switching capacity: see device label!

DC 75 V; 20 W; 0,5 A
St. st. with housing or plug
Hygienic version with cable
St. st. with cable| low voltage| AC 250 V; 100 VA; 1 A
DC 250 V; 50 W; 0,5 A| AC 250 V; 40 VA; 1 A
DC 250 V; 20 W; 0,5 A
St. st. with housing or plug
Plastic with cable
Plastic with housing or plug
Hygienic version with housing
Mini st. st. with cable| safety extra low voltage| AC 50 V; 10 VA; 0,5 A
DC 75 V; 5 W; 0,25 A| AC 50 V; 5 VA; 0,25 A
DC 75 V; 2,5 W; 0,15 A
Mini st. st. With housing or plug
Hygienic version 3A with housing| low voltage| AC 250 V; 50 VA; 1 A
DC 250 V; 50 W; 0,5 A| AC 250 V; 50 VA; 1 A
DC 250 V; 20 W; 0,5 A

Bold versions are standard.

Information fot Float switches which are marked as simple apparatus per EN 60079- 11 section 5.7:
Only for connection to a certified intrinsically safe circuit Ex ia or Ex ib.
Ui ≤ 36 V, Ii ≤ 100 mA, Pi ≤ 0,84 W

Commissioning

Switch on the voltage supply of the connected control device. Fill the vessel and the check the switch points of the magnetic float switch for function.

Warning:
Ensure that the functional check does not start any unintended processes. Always observe the mounting and operating instructions of accessories when commissioning them.

Faults

The following table contains the most frequent causes of faults and the necessary countermeasures.

Magnetic float switch cannot be mounted at the planned place on the vessel| Process connection of the magnetic float switch does not match the process connection of the vessel.| Modification of the vessel
Return to the factory
Process connection at the vessel defective| Rework the thread or replace the screwed coupling
Mounting thread at the magnetic float switch defective| Return to the factory
No or undefined switching function| Electrical connection incorrect| See chapter 5.3 “Electrical connection Check assignment with the aid of the connection diagram.
Temperature contact defective| Return to the factory
Reed contact defective

Caution:

Physical injuries and damage to property and the environment
If faults cannot be eliminated by means of the listed measures, the instrument must be taken out of operation immediately.

• Ensure that there is no longer any pressure present and protect against being put into operation accidentally.
• Contact the manufacturer.
• If a return is needed, please follow the instructions given in chapter “Return”.

Maintenance and Cleaning

When used properly, the magnetic float switches work maintenance-free. They must be subjected to visual inspection within the context of regular maintenance, however, and included in the vessel pressure test.

DANGER!
Work on vessels involves the danger of intoxication and suffocation. No work is allowed to be carried out unless by taking suitable personal protective measures (e.g. respiratory protection apparatus, protective outfit etc.).
Repairs must only be carried out by the manufacturer.
Perfect functioning of the magnetic float switches can only be guaranteed when original accessories and spare parts are used.

CAUTION!
Improper cleaning may lead to physical injuries and damage to property and the environment. Residual media in the dismounted instrument can result in a risk to persons, the environment and equipment.

• Rinse or clean the removed instrument.
• Sufficient precautionary measures must be taken.

1. Prior to cleaning, properly disconnect the instrument from the process and the power supply.
2. Clean the instrument carefully with a moist cloth.
3. Electrical connections must not come into contact with moisture!

CAUTION!
Improper cleaning may lead to damage to the instrument!

• Do not use any aggressive cleaning agents.
• Do not use any pointed and hard objects for cleaning.

Dismounting, Return and Disposal

• Only disconnect the measuring instrument once the system has been depressurised and the power disconnected!
• Wash or clean the dismounted instrument, in order to protect persons and the environment from exposure to residual media.
• Please send a detailed error description with the device to PKP Prozessmesstechnik GmbH, Borsigstraße 24, D-65205 Wiesbaden

FS10

Vertically-Mounted Magnetic

Float Level Sensor

• reliable and robust, heavy duty technology
• mounting thread, tank fittings or flange
• installation at top or bottom of vessel
• versions made of stainless steel, Titanium, PVC, PP or PVDF
• N/C, N/O or SPDT Reed contacts available (PNP or NPN switch output available also)
• Pmax: 80 bar, Tmax: 350 °C
• max. tube length: 6000 mm
• Ex-Version acc. to ATEX

Description:
The FS10 level sensor is based on a float with magnetic transmission technology. The sensor is comprised of a guide tube with embedded Reed contacts, one or more floats with fitted ring magnets and a process connection module. The float is raised by the rising liquid in the tank and operates a Reed contact through the guide tube wall by means of the magnetic field produced by permanent magnets located in the float. This Reed contact can be designed as a NO, NC or changeover function.
Float stops mounted on the guide tube prevent the float from passing the contact, this assures bistable switching.
Consequently, a maximum of 2 contacts per float can be operated. If more contacts are fitted, more floats must be used.

Applications:
FS10 magnetic float level sensors are suitable for monitoring the level of practically all liquids, e.g. as a full or empty tank sensor, for controlling valves and pumps and for alarm function. The potential free Reed contacts fitted in the level sensor make it an ideal control element when coupled with PLC controllers

Versions:
Standard (stainless steel) Minature version (stainless steel) Plastic version (PVC, PP, PVDF) Ex version (on request)
ECTFE coating (on request)

Structure of the measuring instrument:
Each magnetic float level sensor consists of the three key modules below, which, depending on requirements, are available in different models:

• guide tube
• float
• process connection

Secondary instrumentation like contact protection relays complete the measuring system.

Guide tube:

The guide tube is the key component in the level sensor: it houses the reed contacts and can be supplied in a variety of materials and diameters.

Float:

The choice of float is based on the liquid being monitored (corrosion, density), the process parameters (pressure, temperature) and the guide tube materials and diameters. The available float models are listed in the following table.

The selection of the adequate float is best done by technical advise by PKP engineers.
Special floats (e.g. electropolished, increased length, etc.) on request.

Process connection:

Typically, the magnetic float level sensors are screwed in the top of the vessel from inside with a male-threaded fitting (NPT or G, 1/8″ to 2″). When installed in this fashion, the devices are supplied with a PVC or silicone- jacket connection cable. To mount the float level sensor from outside through the top of the vessel the device must be fitted with a tank fitting (NPT or G, 1″, 1 1/2″, or 2″ male thread) or with flanges. In this case it is recommended, that the diameter of the tank fitting or flange is large enough to allow the float to pass through the opening in the top of vessel. In the standard version, an adjustable stop ring is fixed to the end of the guide tube, therefore the float can be removed and afterwards mounted from inside the vessel, if the diameter of the process connection is to small.

Miniature Version, Stainless Steel:

Technical Data:

Guide tube diameter: 8 mm
Guide tube length L: max. 500 mm
Guide tube material: st. st. 1.4571 titanium (others on request)
Process connection:
cable version: screw in connection to top, G 1/8 male
housing version: screw in connection to bottom, G 3/4 AG, G 1 male

Temperature range:

with PVC-cable: -10…+80 °C
with silicone cable: -10…+150 °C
housing version:
NBR / PP-Float: -10…+80 °C
st. st. / titanium float.: -30…+150 °C Tmax for floats: see table 1

Float: stainless steel 1.4571
NBR
PP
titanium
Float diameter: 20…35 mm

Mounting position: vertical +/- 30°

Electrical Data:

Electrical connection: cable made of PVC cable made of silicone
terminal housing: aluminium 64x58x34 mm

Switching function:
(Reed contact)
N/O
N/C
SPDT
(on rising level)

Max. number of contacts: 3 x N/O or N/C or 2 x SPD

Switching position: dimension L1, L2, L3 (from sealing surface, starting from the top)

Switching point distance: min. 20 mm

Switching capacity: depending on switching function (please observe contact protection action, exact details see type plate)

N/O and N/C: 50 VAC, 10 VA, 0,5 A 75 VDC, 5 W, 0,25 A
SPDT: 50 VAC, 5 VA, 0,25 A 75 VDC, 2,5 W, 0,15 A

Protection class: IP65 (plastic housing, plug) IP66/IP68 (alu or stainless steel housing

Possible Float Types:
(see table 1 also)
E1027
B0920
B0923
B0925
E0929
E0929H
T0929

Standard Version, Stainless Steel:

Technical Data:

Guide tube diameter: 12, 14, 18 mm
Guide tube length L: max. 3000 mm (Ø 12, 14 mm) max. 6000 mm (Ø 18 mm)
Guide tube material: stainless steel 1.4571 titanium (others on request)

Process connection:

cable version: screw in connection to top, G 3/8 male, G 1/2 male
housing version: screw in connection to bottom, G 1 1/2 male, G 2 male

flange connections: DIN DN 50…DN 200PN 6… PN 100
ANSI 2“…8“, Class 150…600

Temperature range:

with PVC-cable:-10…+80 °C
with silicone cable -30…+180 °C
housing version: -30…+180 °C
optional: high temp. version: -30…+250 (350) °C
low temperature version: -50…+180 °C
Tmax for floats: see table 1

Float: stainless steel 1.4571
NBR
titanium

Float diameter: 44…120 mm
Mounting position: vertical +/- 30°

Electrical Data:

Electrical connection: cable made of PVC cable made of silicone terminal housing: aluminium
64x58x34 mm (1 contact)
80x75x57 mm
(from 2 contacts)0

Switching function:
(Reed contact)
N/O, N/C
SPDT
(on rising level)

Max. number of contacts: 6 x N/O or N/C or 4 x SPDT

Switching point distance: dimens. L1, L2, L3, (from sealing surface, starting from top)
Switching point distance: min. 20 mm
Switching capacity: depending on switching function (please observe contact protection action, exact details see type plate)

N/O and N/C: 230 VAC, 100 VA, 1 A 230 VDC, 50 W, 0,5 A
SPDT: 230 VAC, 40 VA, 1 A 230 VDC, 20 W, 0,5 A

Protection class: IP65 (plastic housing, plug)
IP66/IP68 (alu or stainless
steel housing

References

• Home - PKP Prozessmesstechnik GmbH

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