Operating Instructions - KSR-TF 511 - with
Contents
1. O H Fig 3 Horizontal installation 1 Switching point 2 Switching point recommended mounting position particularly for adhesive products S S Moisture Use the recommended cables see chapter Connecting to power supply and tighten the cable gland You can give your KSR TF 511 additional protection against moisture penetration by leading the connection cable down ward in front of the cable entry Rain and condensation water can thus drain off This applies mainly to mounting outdoors in areas where moisture is expected e g by cleaning processes or on cooled or heated vessels Fig 4 Measures against moisture penetration Transport Do not hold KSR TF 511 on the tuning fork KSR TF 511 with contactless electronic switch 9 Mounting Pressure Vacuum Handling Welded socket n MSR AMEBLER The process fitting must be sealed if there is gauge or low pressure in the vessel Before use check if the seal material is resistant against the measured product and the process temperature The max permissible pressure is stated in the Technical data in the Supplement or on the type label of the sensor The vibrating level switch is a measuring instrument and must be treated accordingly Bending the vibrating element will destroy the instrument Warning The housing must not be used to screw in2. Thread hygienic fittings Surface quality Standard hygienic version 316L Klingersil C 4400 316L 316L and plastic PEI approx 250 g ca 9 oz G A G1 A NPT or 1 NPT Tri Clamp 1 Tri Clamp 112 bolting DN 25 PN 40 bolting DN 40 PN 40 SMS Ra lt 3 2 um 1 26 in Ra lt 0 8 um 3 15 in Meas accuracy Hysteresis Integration time Frequency Ambient conditions Ambient temperature on the housing Storage and transport temperature approx 2 mm 0 08 in with vertical installation approx 500 ms approx 1200 Hz 40 70 C 40 158 F 40 80 C 40 176 F Process conditions Process pressure Process temperature Standard Process temperature High temper ature version option 1 64 bar 14 5 938 psi 40 100 C 40 212 F 40 150 C 40 302 F Temperature shock no limitation Viscosity dynamic 0 1 10000 mPa s Density 0 7 2 5 g cm 0 025 0 9 oz in 24 KSR TF 511 with contactless electronic switch 819090 N3 6E12e 32139 EN 060618 n MSR KUEBLER Supplement Operation Plug connections Signal lamp LED Green red Red flashing Specification see Connecting to power supply Switch closed Switch open Failure Switch open Output variable Output Contactless electronic switch Modes min max changeover by electrical connection
3. 8L9090 NJ 6E LZE 32139 EN 060618 MSR KUEBLER Product description The packaging of standard instruments consists of environ ment friendly recyclable cardboard For special versions PE foam or PE foil is also used Dispose of the packaging material via specialised recycling companies Storage and transport tem e Storage and transport temperature see Supplement perature Technical data Ambient conditions e Relative humidity 20 85 KSR TF 511 with contactless electronic switch 7 Mounting Switching point La MSR AMEBLER 4 Mounting 4 1 General instructions In general KSR TF 511 can be mounted in any position The instrument must be mounted in such a way that the tuning fork is at the height of the requested switching point The tuning fork has lateral marking notches marking the switching point with vertical mounting The switching point refers to water 1 g cm or 0 036 Ibs in When mounting KSR TF 511 make sure that this marking is at the height of the requested switching point Keep in mind that the switching point of the instrument is shifted if the medium has a density other than water Fig 2 Vertical mounting 1 Switching point approx 13 mm 0 51 in 2 Switching point with lower density 3 Switching point with higher density KSR TF 511 with contactless electronic switch 819090 NJ 6ELZE 32139 EN 060618 MSR KUEBLER Mounting
4. G3 4A 3 4 NPT G1A 1 NPT 221 3mm 27 32 3 3 g Fig 14 KSR TF 511 high temperature version 1 Switching point L Length with G34 A 3 NPT 66 mm 2 6 in L Length with G1 A 1 NPT 69 mm 2 7 in KSR TF 511 with contactless electronic switch 27 Sei KLAR KUEBLER CA KSR KUEBLER Niveau Messtechnik AG Im Kohlstatterfeld 17 69439 Zwingenberg Germany Phone 49 6263 87 0 Fax 49 6263 8799 E mail info de ksr kuebler com www ksr kuebler com CE amp All statements concerning scope of delivery application practical use and operating conditions of the sensors and processing systems correspond to the information avail able at the time of printing Technical data subject to alterations 32139 EN 060618
5. MSR lt MHESLER Product description Scope of delivery Components Area of application 3 Product description 3 1 Configuration The scope of delivery encompasses e KSR TF 511 level sensor e Test magnet e Documentation this operating instructions manual if necessary certificates KSR TF 511 consists of the following components e Housing with electronics e process fitting with tuning fork sn 12409760 Fig 1 KSR TF 511 3 2 Principle of operation KSR TF 511 is a level sensor with tuning fork for level detection It is designed for industrial use in all areas of process technology and can be used in liquids Typical applications are overfill and dry run protection With a tuning fork of only 40 mm length KSR TF 511 can be also mounted e g in pipelines from DN 25 The small tuning fork KSR TF 511 with contactless electronic switch 5 Product description Physical principle Power supply La KSR MMEGLER allows use in vessels tanks and pipes Thanks to its simple and robust measuring system KSR TF 511 is virtually unaffected by the chemical and physical properties of the liquid It functions even under difficult conditions such as turbulence air bubbles foam generation buildup strong external vibration or changing products Fault monitoring The electronics module of KSR TF 511 continuously monitors via frequency evaluation the following criteria e Stron
6. max min Max detection or overflow overfill protection Min detection or dry run protection Voltage supply Supply voltage Domestic current requirement Load current 20 253 V AC 50 60 Hz 20 253 V DC approx 3 mA via load circuit min 10 mA max 250 mA Electrical protective measures Protection Valve plug DIN 43650 IP 65 Valve plug QuickOn DIN 43650 IP 65 Overvoltage category Protection class Approvals Overfill protection acc to WHG KSR TF 511 with contactless electronic switch 25 Supplement MSR KUEBLER 9 2 Dimensions KSR TF 511 standard version 36mm 1 27 64 27mm 1 1 46 29mm 1 9 64 a Si w2 z 032 E E 8 S G3 4A 3 4 NPT G1A 1 NPT 21 3mm Fn 27 32 Fig 13 KSR TF 511 standard version Thread G34 A G1 A 34 NPT or 1 NPT valve plug DIN 43650 Thread G34 A G1 A NPT or 1 NPT valve plug DIN 43650 with QuickOn connection Switching point Length with G34 A 34 NPT 66 mm 2 6 in Length with G1 A 1 NPT 69 mm 2 7 in rroba 26 KSR TF 511 with contactless electronic switch 819090 NJ 6ELZE 32139 EN 060618 KS KUEBLER Supplement KSR TF 511 high temperature version 36mm 1 27 64 27mm 1 1 46 188mm 7 13 30 032
7. Lue KER KUEBLER CA Operating Instructions KSR TF 511 with contactless electronic switch Contents MSR KUEBLER Contents 1 About this document Ts SFUNCHON 435 oscil eee ke eS hee ates 3 1 2 Target group 0 cece eee eee 3 1 3 Symbolism used 220 055 3 2 For your safety 2 1 Authorised personnel 2005 4 2 2 Appropriate use 2 0 0 055 4 2 3 Warning about misuse 4 2 4 CEconformity 2 0 055 4 3 Product description 3 1 Configuration 2 2 2 eee ee 5 3 2 Principle of operation 05 5 3 3 Operation s eri repe eta ee oe 6 3 4 Storage and transport 6 4 Mounting 4 1 General instructions 200054 8 4 2 Mounting information 10 5 Connecting to power supply 5 1 Preparing the connection 13 5 2 Wiring plans is20 e220 tae oe ich naa Aa 13 6 Setup 6 1 Indication of the switching status 17 6 2 Function test eeens ce a a a 17 6 3 Function chart s s saaa 18 7 Maintenance and fault rectification 7 1 Maintenance 20000 005 19 7 2 Fault rectification nauena aaaea 19 7 3 Exchange of the electronics 20 7 4 Instrument repair 2 2 eee eee eee 22 8 Dismounting 8 1 Dismounting procedure 23 8 2 Disposal s 524 ertsd yu renna a Bee 23 9 Supplement 9 1 Technical data aaa aaaea aaa
8. ach the recommended installation position In adhesive and viscous products the surfaces of the tuning fork should protrude into the vessel to avoid buildup Therefore sockets for flanges and mountings bosses should not exceed a certain length 30mm 1 3 46 SH Fig 6 Adhesive products If KSR TF 511 is mounted in the filling stream unwanted switching signals may be generated Mount KSR TF 511 ata location in the vessel where no disturbing influence from e g filling openings agitators etc can occur KSR TF 511 with contactless electronic switch 11 Mounting MSR KUEBLER Flows To minimise flow resistance caused by the tuning fork KSR TF 511 should be mounted in such a way that the surfaces of the fork are parallel to the product movement 12 KSR TF 511 with contactless electronic switch 819090 NJ 6E LZE 32139 EN 060618 Connecting to power supply a KERI KUEBLER Note safety instructions Selecting the connection ca ble Cable glands Housing overview 5 Connecting to power supply 5 1 Preparing the connection Always observe the following safety instructions e Connect only in the complete absence of line voltage KSR TF 511 is connected with standard cable with round cross section Depending on the plug connection you have to select the outer diameter of the cable respectively so that the seal effect of the cable gland is en
9. ch 009090 ms gt i S E Ne Fig 9 Connection valve plug QuickOn DIN 43650 Compression nut Cable Split taper socket Seal insert Strand Plug housing The instrument is used for direct control of relays contactors magnet valves warning lights horns etc It must not be operated without intermediately connected load because the electronic would be destroyed if connected directly to mains It is not suitable for connection to low voltage PLC inputs Domestic current is temporarily lowered below 1 mA after switching off the load so that contactors whose holding current is lower than the constant domestic current of the electronics 3 mA are reliably switched off AaAAwWMhM KSR TF 511 with contactless electronic switch 15 Connecting to power supply La MSR MUEBLER Max Q PE PE Fig 10 Wiring plan contactless electronics switch with valve plug DIN 43650 PE Protective ground RL Load resistor contactor relay etc 16 KSR TF 511 with contactless electronic switch 819090 NJ 6ELZE 32139 EN 060618 MSR Set up Gm AMESLER A 6 Set up 6 1 Indication of the switching status The switching status of the electronics can be checked on the upper part of the housing 6 2 Function test KSR TF 511 has an integrated test switch which can be activated magnetically Proceed as follows to test the instru ment gt Hold the test mag
10. ctification 7 1 Maintenance When used as directed in normal operation KSR TF 511 is completely maintenance free 7 2 Fault rectification KSR TF 511 offers maximum reliability Nevertheless faults can occur during operation These may be caused by the following e g Sensor Process Power supply Signal processing The first measure to be taken is checking the output signal In many cases the causes can such be determined and failures can be rectified If the following measures are not successful you can call the VEGA service hotline in urgent cases under the phone no 49 1805 858550 The hotline is available to you 7 days a week round the clock Since we offer this service world wide the support is only available in the English language The service is free of charge only the standard telephone costs will be charged Control lamps off Voltage supply interrupted gt Check the voltage supply and the cable connection gt Exchange the electronics module Signal lamp flashes red There was no load connected when connecting to power supply gt Connect the instrument correctly gt Check if the tuning fork is damage or extremely corroded Frequency error gt Adjust the instrument correctly KSR TF 511 with contactless electronic switch 19 Maintenance and fault rectification La KSR MMESLER The signal lamp flashes alternately red and green Shortcircuit or overload gt Check th
11. e electrical connection 7 3 Exchange of the electronics To exchange the electronics in case of failure it is not necessary to dismount the instrument Dismounting the electronics module can destroy the housing seal Therefore only open the instrument if you want to insert a new electronics module The housing seal is supplied with the electronics module You need an electronics module type SWESOT or SWESOC If you want to use an electronics module with a different signal output e g transistor output SWE50T you can download the suitable operating instructions manual from our homepage under Downloads Take note of the specifications in the respective operating instructions manual Proceed as follows to exchange the electronics module Separate KSR TF 511 from operating voltage Loosen fixing screw 1 of the valve plug 2 with a wrench Remove valve plug 2 acc to drawing Remove lateral fixing screw 7 with a crosstip screwdriver Pull electronics module 4 carefully out of the housing 8 Remove the plug of the connection cable 6 from the socket on the oscillator 4 7 Set the 16 step rotating switch 5 of the new replacement electronics module 4 to the value of the defective electronics module oak won 8 Insert the connection cable 6 in the socket of the new electronics module 4 9 Insert electronics module 4 into the housing 8 Make sure that the lateral thread on the electronics module is above the hol
12. e on the housing 8 10 Push the electronics module 4 flush into the housing 8 11 Screw in the lateral fixing screw 7 with a crosstip screwdriver 12 Plug the valve plug 2 to the instrument make sure that the profile seal 3 is placed correctly 20 KSR TF 511 with contactless electronic switch 819090 NJ 6E LZE 32139 EN 060618 MSR X KUEBLER Maintenance and fault rectification 13 Tighten fixing screw 1 with a wrench KSR TF 511 is again ready for operation ee Fig 12 Exchange the electronics module Fixing screw Valve plug DIN 43650 Profile seal Electronics module Rotary switch 16 steps Plug connector Fixing screw Housing ANA aAARwWDH A KSR TF 511 with contactless electronic switch 21 Maintenance and fault rectification La KER MMESLER 7 4 Instrument repair If a repair of KSR TF 511 is necessary please proceed as follows Clean the instrument and pack it damage proof Attach a description of the fault the ambient conditions and measured product to the instrument If necessary attach a safety sheet to the instrument Please send the instrument to the respective address of your agency or the main office in Germany In Germany pleased send the instrument directly to our main office 22 KSR TF 511 with contactless electronic switch 819090 N3 6E12e 32139 EN 060618 MSR Dismounting Gm AMESLER A 8 Dismounting 8 1 Dis
13. ea aaa 24 9 2 Dimensions 0 0 00 cee ee eens 26 2 KSR TF 511 with contactless electronic switch 819090 NJ 6ELZE 32139 EN 060618 MSR About this document Gm AMESLER u0 De 1 About this document 1 1 Function This operating instructions manual has all the information you need for quick setup and safe operation Please read this manual before you start setup 1 2 Target group This operating instructions manual is directed to trained qualified personnel The contents of this manual should be made available to these personnel and put into practice by them 1 3 Symbolism used Information tip note This symbol indicates helpful additional information Caution If this warning is ignored faults or malfunctions can result Warning If this warning is ignored injury to persons and or serious damage to the instrument can result Danger If this warning is ignored serious injury to persons and or destruction of the instrument can result Ex applications This symbol indicates special instructions for Ex applications List The dot set in front indicates a list with no implied sequence Action This arrow indicates a single action Sequence Numbers set in front indicate successive steps in a procedure KSR TF 511 with contactless electronic switch 3 For your safety La KER AEBLER 2 For your safety 2 1 Authorised personnel All operations described in this operating instruct
14. g corrosion or damage on the tuning fork e loss of vibration e Line break to the piezo drive If a malfunction is detected or in case of power failure the electronics takes on a defined switching condition i e the contactless electronic switch opens safe condition The tuning fork is piezoelectrically energised and vibrates at its mechanical resonance frequency of approx 1200 Hz The piezos are fixed mechanically and are hence not subject to temperature shock limitations The frequency changes when the tuning fork is covered by the medium This change is detected by the integrated oscillator and converted into a switching command KSR TF 511 is a compact instrument i e it can be operated without external evaluation system The integrated electronics evaluates the level signal and outputs a switching signal With this switching signal a connected device can be directly activated e g a warning system a PLC a pump etc The exact range for power supply is stated in the Technical data in the Supplement 3 3 Operation The switching status of KSR TF 511 can be checked with closed housing signal lamp Products with a density gt 0 7 g cm gt 0 025 Ibs in can be detected 3 4 Storage and transport Packaging Your instrument was protected by packaging during transport Its capacity to handle normals loads during transport is assured by a test according to DIN 55439 6 KSR TF 511 with contactless electronic switch
15. ions manual must be carried out only by trained specialist personnel authorised by the operator For safety and warranty reasons any internal work on the instruments must be carried out only by personnel authorised by the manufacturer 2 2 Appropriate use KSR TF 511 is a sensor for level detection Detailed information on the application range of KSR TF 511 is available in chapter Product description 2 3 Warning about misuse Inappropriate or incorrect use of the instrument can give rise to application specific hazards e g vessel overfill or damage to system components through incorrect mounting or adjustment 2 4 General safety instructions KSR TF 511 is a high tech instrument requiring the strict observance of standard regulations and guidelines The user must take note of the safety instructions in this operating instructions manual the country specific installation standards e g the VDE regulations in Germany as well as all prevailing safety regulations and accident prevention rules 2 5 CE conformity KSR TF 511 is in CE conformity with EMC 89 336 EWG fulfils Namur recommendation NE 21 and NE 23 and is in CE conformity with NSR 73 23 EWG Conformity has been judged according to the following standards e EMC Emission EN 61326 1997 class B Susceptibility EN 61326 1997 A1 1998 e LVD EN 61010 1 2001 KSR TF 511 with contactless electronic switch 819090 N3 6E12e 32139 EN 060618 n
16. mounting procedure Warning Before dismounting be aware of dangerous process con ditions such as e g pressure in the vessel high temperatures corrosive or toxic products etc Take note of chapters Mounting and Connecting to power supply and carry out the listed steps in reverse order 8 2 Disposal The instrument consists of materials which can be recycled by specialised recycling companies We use recyclable materials and have designed the electronic modules to be easily separable WEEE directive 2002 96 EG This instrument is not subject to the WEEE directive 2002 96 EG and the respective national laws in Germany e g ElektroG Pass the instrument directly on to a specialised recycling company and do not use the municipal collecting points These may be used only for privately used products according to the WEEE directive Correct disposal avoids negative effects to persons and environment and ensures recycling of useful raw materials Materials see Technical data If you cannot dispose of the instrument properly please contact us about disposal methods or return KSR TF 511 with contactless electronic switch 23 Supplement La MSR lt MMESLER 9 Supplement 9 1 Technical data General data Material 316L corresponds to 1 4404 or 1 4435 Materials wetted parts Tuning fork Process seal Process fittings Materials non wetted parts Housing Weight Process fittings
17. net accessory to the magnet symbol on the instrument housing Fig 11 Function test The test magnet changes the current switching condition of the instrument You can check the change on the signal lamp Please note that the connected instruments are activated during the test If KSR TF 511 does not switch over after several tests with the test magnet you have to check the plug connection and the connection cable and test the instrument again If there is no switching function the electronics will be defective In this case you have to exchange the electronics or return the instrument to our repair department Caution KSR TF 511 with contactless electronic switch 17 Set up MSR AMEBLER It is absolutely necessary that you remove the test magnet after the test from the instrument housing 6 3 Function chart The following chart provides an overview of the switching conditions depending on the adjusted mode and level Level Switching status Control lamp Mode max O Switch closed Green Mode max S Switch open red h Mode min a Switch closed Green Mode min N Switch open red y Failure any Switch open flashes red 18 KSR TF 511 with contactless electronic switch 819090 NJ 6ELZE 32139 EN 060618 n MSR lt MHESLER Maintenance and fault rectification Causes of malfunction Fault rectification 24 hour service hotline 7 Maintenance and fault re
18. sured e Valve plug DIN 43650 4 5 7mm e Valve plug QuickOn DIN 43650 3 5 6 5 mm Use cable with a round wire cross section and tighten the cable gland When mounting outdoors on cooled vessels or in humid areas in which cleaning is carried out e g with steam or high pressure it is particularly important to seal the cable gland 5 2 Wiring plan Fig 7 Overview of the connection versions 1 Valve plug DIN 43650 2 Valve plug DIN 43650 with QuickOn connection KSR TF 511 with contactless electronic switch 13 Connecting to power supply La MSR MUEBLER Plug versions Valve plug DIN 43650 For this plug version standard cable with round wire cross section can be used Cable diameter 4 5 7 mm protection IP 65 6 q i Fig 8 Connection valve plug DIN 43650 Pressure screw Pressure disk Seal ring Fixing screw Seal washer Plug housing Plug insert Profile seal Control lamp 10 KSR TF 511 Valve plug QuickOn DIN 43650 For this plug version you can use standard cable with round wire cross section The inner cables must not be dismantled The plug connects the cables automatically when screwing them in Cable diameter 3 5 6 5 mm protection IP 65 OCONAAAWNDH A 14 KSR TF 511 with contactless electronic switch 819090 NJ 6ELZE 32139 EN 060618 Gm MSR AMESLER Connecting to power supply Contactless electronic swit
19. the instrument Applying tightening force on the housing can damage its internal mechanical parts To screw in use the hexagon above the thread 4 2 Mounting information For welded socket with O ring in front and welding marking KSR TF 511 has a defined thread runout point This means that every KSR TF 511 is in the same position after being screwed in Remove therefore the supplied flat seal from the thread of KSR TF 511 This flat seal is not required when using a welded socket with front flush O ring Before welding unscrew KSR TF 511 and remove the rubber ring from the welded socket The welded socket has a marking notch For horizontal mounting weld the socket with the notch facing upward or downward in pipelines aligned with the direction of flow 10 KSR TF 511 with contactless electronic switch 819090 NJ 6ELZE 32139 EN 060618 Mounting Gm MSR AMESLER Adhesive products Inflowing material Fig 5 Marking on the welded socket 1 Marking In case of horizontal mounting in adhesive and viscous products the surfaces of the tuning fork should be vertical in order to reduce buildup on the tuning fork The position of the tuning fork is marked by a marking on the hexagon of KSR TF 511 With this you can check the position of the tuning fork when screwing it in When the hexagon touches the seal the thread can still be turned by approx half a turn This is sufficient to re
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