Installation and Operating Instructions
Contents
1. 74 3 72 9 206 8 344 7 KSR Kuebler Limited Product Warranty When used in accordance with the applicable documentation all KSR Kuebler level controls are warranted free of defects in workmanship or materials to the original end user as follows from the date of original factory shipment Five 5 full years for Level Switches amp Magnetic Level Indicators Two 2 full years for Level Transmitters When returned prepaid within the warranty period and upon factory inspection of the unit and verification of a defect KSR Kuebler will repair or replace at its discretion the defective unit at no cost other than transportation KSR Kuebler shall not be liable for direct or consequential equipment damage due to corrosion nor any incompatibility of the materials of construction of the equipment with the process and or equipment of the user KSR Kuebler shall not be liable for any type of damage or loss direct or consequential due to misapplication mis specification misuse damage due to mechanical or electrical overloading improper mounting or failure of the device KSR Kuebler shall not be liable for any direct or consequential damage expense or labor claims stemming from the use or installation of KSR Kuebler equipment Any unauthorized modification repair or rework of KSR Kuebler equipment renders this warranty null and void THE WARRANTIES SET FORTH ABOVE ARE2. EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES WHETHER STATUTORY EXPRESS OR IMPLIED INCLUDING ALL WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND ALL WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF TRADE KSR f MUEBLER A division of the WIKA Group KSR Kuebler of America Inc KSR Kuebler Niveau Messtechnik AG 950 Hall Court Heinrich Kuebler Platz 1 Deer Park Texas 77536 69439 Zwingenberg am Neckar Phone 713 475 0022 Phone 49 6263 87 0 Fax 713 475 0011 Fax 49 6263 87 99 info ksr usa com info ksr kuebler com www ksr usa com www ksr kuebler com
3. KOR KUEBLER Installation and Operating Instructions Please retain for future usage Level Transmitters for Magnetic Level Gauges INTRODUCTION KSR Kuebler level transmitters are primarily used for continuous measurement of liquid levels They operate by using the field of a magnet inside the float to actuate reed switches inside the device rod A measuring network reed switches and precision resistors built into the transmitter rod provides an internal potentiometer style signal proportional to the position of the float The resolution of the transmitter is dependent on the number of switches per unit length and is customer specified along with device length at the time of order The output of the device is two wire 4 to 20 ma and can be configured to increase or decrease with float level For your convenience please enter Model Serial 0 59 15mm j p 98 25mm TO 18mm pa I 98 25mm 1 96 50mm 1 96 50mm 100 j 20mA 100 20mA L Meastring Range i hei Fresa L Length of Span L Length Measuring Range Ji 0 1 0 4mA 4mA 5 25 131mm 4 50 20 114mm 50 8mm I sie 132mm 80mm 1 4 50 63 5mm 5 90 150mm 3 62 3 75 95mm 2 50 63 5mm 2 95 75mm 82mm SIDE FRONT SIDE VIEW FRONT VIEW KSR Kuebler level transmitters have approvals up to Explosion Proof Class 1 Divis
4. and and observing the result The 0 and 100 points should be re checked to ensure they are set correctly MAINTENANCE KSR Kuebler level transmitters operate free from maintenance and wear when used properly A periodic visual inspection and re qualification test should be performed at a regular interval QUESTIONS For customer support please call 1 888 KSR LEVL 577 5385 between the hours of 8 00 a m and 5 00 p m Eastern time Please have your model number and serial number found on the device label handy Pressure Temperature Ratings ANSI Flanges acc to ASME ANSI B16 5 2003 Material group 2 2 SS 316 SS 316 H SS 316 Ti Working Pressures by Classes in bar Temperature in C so 184 481 962 1443 2406 4009 7 4 5 to wo po o 20 30 102 316 632 949 1581 2635 35 350 ss 375 74 299 598 896 1494 2490 400 65 294 589 883 1472 2453 Pressure Temperature Ratings ANSI Flanges acc to ASME ANSI B16 5 2003 Material group 2 3 SS 316 L Working Pressures by Classes in bar cme 150 aw eoo in C po 50 153 400 800 100 133 348 696 150 120 314 628 200 112 292 583 250 105 275 549 300 100 261 521 35 93 255 510 350 84 251 501 400 65 243 486 124 1 120 1 104 4 94 2 87 5 82 4 78 2 76 4 75 2
5. ay two clip leads are required to connect the indicator to the puck baseboard Connect the clip leads in the same polarity as the indicator plugs into the baseboard making sure no shorts circuits ate created note the indicator will only plug into the baseboard one way Units with no built in display do not require jumpers Power up the device using a suitable calibration source insuring no processes will be affected during calibration Move the float to the desired 0 position and adjust the zero adjustment potentiometer on the puck until the display reads 0 or the calibrator indicates 4 ma Move the float to the desired 100 position and adjust the span potentiometer on the puck until the display reads 100 or the calibrator indicates 20 ma Move the float back and forth several times to check both settings The indicator unit is factory calibrated to read 0 to 100 for 4 to 20 ma respectively and can be calibrated with a suitable supply by adjusting the zero and span pots of the upper board of the display unit The pot on the lower display board should not be adjusted Install the indicator unit and replace the plastic label around the display Screw the cover back on the display and tighten Replace and tighten the housing cover and energize the power supply for the connected control unit s Fill the tank in order to observe that the readout changes smoothly The level transmitter can also be tested manually by moving the float by h
6. et is installed correctly and tighten all fasteners to the correct torque Replace the float s and retaining collar s in the correct orientation if previously removed Transmitters with remote electronics must be connected using three conductor shielded cable see Fig 4 for Explosion Proof drawing 095 3201 001 Pg 3 for single puck Intrinsically Safe applications or drawing 095 3201 001 Pe 5 for dual puck Intrinsically Safe applications The symbols screened on the board show the connections to the terminal blocks By reversing the max and min connections at the puck the gauge readout can be reversed relative to the float position see Fig 1 Power Supply di E y Display or control device 77 4t020 Pd LOOP ON q A DA Z MALLINX PA x b JANSSIAA SPAN ZERO 609 AT A DI DOSES 5 RTD XMITTER 1 K psgz aes tetsz ES xy Figure 4 Explosion Proof Wiring for Transmitters With Remote Electronics 3 095 3201 001 Page S Remote Foi hd Tae aj0uay G abod 100 60 QUALIFICATION WARNING Make sure any tests performed in qualification do not unintentionally start any processes resulting in loss of control WARNING Never open cover in hazardous areas while circuits are energized Follow all safety work procedures and lock out circuits before servicing or inspection To calibrate units with built in displ
7. ion 1 Group B depending on the ordered configuration They can be used for Intrinsically Safe applications up to Group A with the addition of an agency approved safety barrier All materials which come into contact with the liquid must be corrosion resistant and are customer specified The liquid to be monitored must not be heavily contaminated and must not have a tendency to crystallize or solidify INSTALLATION NOTES e KSR Kuebler level transmitters must be installed within 30 degrees of vertical to function correctly They must not be installed within 3 feet of strong electromagnetic fields e When installing a level transmitter in a vessel connection smaller than the diameter of the float requiring removal of the float s mark the top of the float s and the position of the retaining collar s Be sure to replace the float s in the same orientation Reposition and securely tighten the retaining collar s e All witing and hardware must be in accordance with applicable standards and regulations Avoid running 4 to 20 ma cabling next to AC power wiring always use shielded cable When installing in a location requiring Intrinsic Safety an agency approved barrier must be used see Installation Drawings e Install a pour seal fitting within 18 inches of the housing to prevent water from entering the housing and for compliance with the National Electrical Code INSTALLATION Transmitters with Integral Electronics Install KSR level tran
8. smitters according to their type flange thread or bracket using the correct gasket or compound for sealing Make sure the gasket is installed correctly and tighten all fasteners to the correct torque Replace the float s and retaining collar s in the correct orientation if previously removed Note it may be easier to calibrate the unit before installation if possible Transmitters with integral electronics puck and or display must be connected in a series loop with the readout or data acquisition device and the power supply Shielded cable must be used for noise immunity and for Intrinsically Safe applications an agency approved safety barrier must be installed A ground wire must be provided and connected to the ground block inside the housing To connect a transmitter with a built in digital display unscrew and remove the housing cover and carefully remove the plastic label from around the display by grasping each side and pulling upwards Remove the digital display by carefully pulling up on two diagonal sides of the display The indicator is held in place by two banana plugs which plug into the baseboard where the 4 to 20 ma puck is mounted Field wiring connections are made to a two point compression type terminal block located on the baseboard see Fig 2 for Explosion Proof or drawing 095 3201 001 Pg 1 for Intrinsically Safe applications Attach a ground wire directly to the ground screw inside the housing To connect a transmitter wi
9. thout a built in display unscrew and remove the housing cover Field wiring connections are made directly to the puck see Fig 3 for Explosion Proof drawing 095 3201 001 Pg 2 for single puck Intrinsically Safe applications or drawing 095 3201 001 Pg 4 for dual puck Intrinsically Safe applications Attach a ground wire directly to the ground screw inside the housing The transmitter comes pre wired from the factory however to reverse the reading of the gauge relative to the float position it is necessary to reverse the max and min connections on the puck see Figure 1 4to207 LOOP Ne as Base Board s VA SPAN ZERO Puck A X 1 5 z A CRLSS Figure 1 Component Identification Power Supply y SS 7 Displ Z a al 4t020 SP AVE SC LOOP ON control device fa A 4 po ENS SPAN gt ZERO T SSSSS x S z PRESS i Figure 2 Explosionptoof Wiring for Transmitters with Integral Display Power Supply Display or control device ARM MAX MIN 1 nun aa Figure 3 Explosionproof Wiring for Transmitters without Integral Display 1 3804 100 I02 G60 ojds g 41 218 2 2509 100 I02 S60 e Y y 2004 100 102 S60 INSTALLATION Transmitters with remote electronics Install KSR level transmitters according to their type flange thread or bracket using the correct gasket or compound for sealing Make sure the gask
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