Baumer 11109132 CleverLevel Switch LFFS Instruction Manual

Operating instructions
CleverLevel switch, LFFS

CleverLevel switch, type LFFS is a universal level switch, which can be used for all applications in liquids and solids with a DCvalue above 1.5

Safety instructions

This instrument is constructed and tested according to the current EU directives and packed in a 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 is designed to detect levels in tanks, and media separation and provide empty-pipe detection or dry-run protection for pumps.
By means of the FlexProgrammer 9701, the output can be configured to either NPN, PNP, or digital output signal. Damping of the output signal can be activated in case of a fluctuating media level, e.g. during tank filling.
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. 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, yogurt, toothpaste, and ketchup.
Even dry media can be measured, e.g. sugar or flour. The Level Switch LFFS is resistant to CIP and SIP agents. Hygienic installation is also possible with the comprehensive range of accessories, see the overview on page 6.

WARNING
When the top cover is removed, do not look directly at the blue LED with unshielded eyes, or damage to the retina may occur!
This product contains no replaceable parts. In case of malfunction, the product must be shipped to Baumer for repair.

Measuring principle

An electrode inside the sensor tip builds a capacitor together with the surroundings. The medium with its dielectric constant (DC value) is defining the capacitance value. A resonance circuit is created in combination with a coil in the sensor head. Switching signal tripping is according to the measured resonance frequency and the programmed trigger thresholds.

Dimensions

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Mounting
Please refer to the “Accessories” data sheet. The welding part has an engraved arrow or a leakage hole. When the product has been mounted correctly the gland or M12 plug will align with the arrow/leakage hole plus/minus a few degrees.
Make sure that the gland/plug is pointing downwards to prevent fluids from penetrating into the instrument.
Use only the authorized special designed accessories. The product warranty is void when installed with other adapters.
Do not use PTFE, fiber, 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.

Mounting instructions for sliding connection:

1. Clean the sliding shaft.
2. Mount the smallest ring against the media as indicated.
3. Tighten the G1/2 Hygienic sliding nipple at 25…30 Nm.
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 a sliding connection can be mounted in installations with a static pressure of up to 16 bar.
To prevent personal injuries or property damage it is essential that the safety wire is mounted correctly and is undamaged.

Mounting
The industrial versions with thread must be sealed e. g. by a gasket or Teflon® tape and tightened into the counterpart.
Installation of hygienic 3-A approved and EHEDG certified products, please refer to below:

1. Use only a 3-A-approved counterpart.
2. The leak detection port should be visible and drained.
3. Mount the adapter in a self-draining position/angle.
4. Level the inner surface of the pipe with the counterpart
5. The 3-A mark or the arrow shall be placed upwards.
6. Welding should be ground to Ra ≤ 0.8.
7. Tighten the instrument in the adapter with a torque of 15…20 Nm.

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After installation:

• Check the leak tightness of the sleeve.
• Check the tightness of cable glands or M12 plug.
  The switch provides IP67 protection in cable version or if installed with IP67-compliant M12 cable. Switch installation using an IP69K cable ensures IP69K conformity.

NOTE
The M12 cable rotating nut must be tightened by hand force only.
Max. torque is 0.6 Nm. Do not use any tool.

If the seal is leaking and the media appears in the leak detection port, the seal is to be changed immediately.
Before reassembly, clean the hole and inside of the connection with detergent and sanitizing liquid. Use a small brush. Verify that all of the inside areas is completely clean.
Reassemble and verify that the connection is tight.
Do not use Teflon, elastomer, or other types of gaskets for the hygienic process connection featuring a conical seal.
NOTE
The CleverLevel switch is to be mounted in a closed metal pipe, tank, or container.

WHG leakage and overfill protection
The LFFS is WHG certified for leakage and overfills protection. All documentation must be available at the place of use and can be found on the product page at www.baumer.com

Mounting connections

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DIN 11864-1-A
DN 40: ZPH3-3254
DN 50: ZPH3-3255| Welding Ø35 for tank/tube
ZPW2-324
|
Adapter
EH FTL
G¾A: ZPH1-32BA
G1A: ZPH1-32CB
VS
G¾A: ZPH1-32BC
G1A: ZPH1-32CD| Welding
to pipe extrusion
DN 25…DN 50: ZPW2-326
DN 65…DN150: ZPW2-327
3-A approved
DN 25…DN 50: ZPW3-326
DN 65…DN 150: ZPW3-327
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Adapter
G½ → G1
ZPH1-32C0| Adapter, industrial
G½ → G1: ZPI1-32B
G½ → G1½: ZPI1-32D
G½ → G2: ZPI1-32E
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Adapter, industrial
Sliding connection
G½ → G½ DIN 3852-E
ZPI1-32A| On a welding adapter, there is an arrow or a leakage hole.
This must be placed downwards when welding the adapter into a tank (horizontal position).
This assures that the electrical connection will be pointing downwards

Refer to the adaptor instruction manual for further information

NOTE:
The LFFS must be mounted in a Baumer mounting connection.
If not, Baumer does not guarantee correct function or tightness.

Media temperature and external length for sliding connection

LFFS-xx1.x / LFFS-xx2.x
Media temperature °C| LFFS-xx3.x and LFFS-xx4.x
Media temperature °C
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For CIP/SIP

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.

It is essential that the max. ambient temperature for the electronics is never exceeded (85°C). For ATEX-approved products please refer to ATEX data.
For example, how to read the External length curve:
Example: Media temperature / Ambient temperature / External length
160°C 60°C 120 mm

• A 250 mm sliding connection is mounted in a tank with a total insertion 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 and 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 were changed from standard factory settings, it is necessary to re-adjust the new switch to the 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 a very exact set point is required, a new teach-in or adjustment by the FlexProgram must be performed.

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.

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Using the FlexProgrammer 9701 alone and Teach-In

FlexProgrammer 9701 stand-alone menu

Press

Turn on FlexProgrammer if in sleep mode Empty configuration
Search for product LFFS/LBFS configuration

| Product| FFS / 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%

Press or to browse the menus
to access the current menu point
to return to the previous menu
and simultaneously reset FlexProgrammer and go into sleep mode

Teach-In
Press
and simultaneously Select Menu “Teach-In”
Search for product
= Product LFFS/LBFS
At the 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.

operation with a 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 does 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 setting will be confirmed by a pulsing light intensity 3 times.

powering off and on and remaking the Teach-In.
Alternatively, remake the Teach-In configuration by use of the  FlexProgram and the
FlexProgrammer 9701

Electrical connection

M12 plug:

1 Brown
2 White*| 3 Blue
4 Black
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WARNING

• 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.
PNP, NPN, or Digital
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Output| 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

ATEX
Conditions for Ex certification

Connection type| Ambient temperature| Media temperature (max. allowed)| Note
---|---|---|---
G1/2 hygienic 3A DN38| -40 … +85 °C| +85 °C|
-40 … +60 °C| +95 °C| 1)
-40 … +40 °C| +115 °C| 1)
100 mm
Sliding connection| -40 … +85 °C| +85 °C|
-40 … +60 °C| +155 °C| 1)
-40 … +40 °C| +175 °C| 1)
250 mm
Sliding connection| -40 … +85 °C| +85 °C|
-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, zone 1, or zone 2 with a barrier.

Note:
There is an electrical connection between the intrinsic safe circuit and housing due to the measurement principle

Ex-data

I  <0.1 A
P  <0.75 W

LFFS-1xx.x with NPN output

Note:
For NPN output only!
A standard barrier may be used

LFFS-1xx.x with PNP output

Note:
For PNP output the barrier module PROFSI3-B25100-ALG-LS is required for functional purposes.

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 without a barrier.

Ex-data

ATEX Gas nA
A Level Switch LFFS-3xx.x is Ex nA IIC 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.

Ex-data

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.

Manufacturer
Declaration of Conformity (EN) The undersigned declares on behalf of the manufacturer, that the products to which this declaration relates comply with all relevant provisions of the listed EU directive(s) and are based on the specified standard(s).

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Directives:
2014/30/EU, 2014/34/EU, 2011/65/EU (incl. EU 2015/863)
Regulations (if applicable):
Standards / Technical Specifications:
EN 60079-0:2012+A11:2013;
EN 60079-11:2012;
EN 60079-15:2010;
EN 60079-26:2015;
EN 60079-31:2014;
EN 61326-1:2013;
EN IEC 63000:2018;
Remarks:
x: any figures or letter or character LFFS-1: Ex II 1G Ex is I IC T5, LFFS-2: Ex II 1D Ex tD A20 IP67 100°C, LFFS-3: Ex II 3G Ex nA II T5
Notified body (if applicable):
Intertek 0359 Cleeve Road, Leatherhead Surrey, KT22 7SB
Intertek Italia S.p.A 2575 Via Miglioli, 2/A 20063 Cernusco sul Naviglio (MI)
Type examination certificate (if applicable): ITS09ATEX16438X ITS09ATEX26328X
Product group:
Liquid level measurement
Type(s):
LFFS-1xx.x; LFFS-2xx.x; LFFS-3xx.x;

Baumer A/S
Runetoften 19
DK-8210 Aarhus V
CVR: DK25275071
VAT. No.: DK11841813| DK Phone +45 8931 7611
SE Phone +46 (0) 36 13 9430
sales.dk@baumer.com
sales.se@baumer.com
www.baumer.com| Danske Bank: SWIFT: DABADKKK
(DKK) Konto: 4387-3627293852
(EUR) IBAN: DK0230003617021021
(SEK) Bankgiro: 5220-9632
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For further information please refer to www.baumer.com
www.baumer.com
Operating instructions: 11109132

References

• Baumer - Passion for Sensors | Baumer USA

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