ACS KAK User manual

Technical manual BA 0722
KAK / KLK
Filling level limit switch
for conductive filling level supervision
in electrical conductive liquids
Detects up to two limit values
Useable
for filling level resp. limit value detection in liquid container
as overflow protection in container
as dry run protection for pumps in pipelines
for two-position-control in plants
Wide application range
for process temperatures from -40 °C to +100 °C
for process pressures from -1 bar to +10 bar
materials for aggressive filling liquids
Measuring range adjustable up to 200kresp. 5µS/cm
Wide range power supply from 20 to 253V AC and DC
Relay output or PNP switching output
[e-mail]
www.acs-controlsystem.de
+49 8721 / 9668-0
ACS Control-System GmbH
Lauterbachstr. 57
D- 84307 Eggenfelden
FEEL FREE TO
CONTACT US

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KAK / KLK
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Index
Application field ............................................................................................................ 3
Function ............................................................................................................... 3 / 4 / 5
Safety notes .................................................................................................................. 6
Installation ............................................................................................................... 6 / 7
Maintenance ................................................................................................................. 7
Repair ............................................................................................................................ 7
Electrical connection .................................................................................................... 8
Operation and display elements .................................................................................. 9
Technical data ................................................................................................ 10 / 11
Dimension drawings .............................................................................. 12 / 13 / 14 / 15
Order code overview ................................................................................................... 16

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KAK / KLK
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Application field
The filling level limit switch KAK resp. KLK is used, to evaluate one or two filling levels resp. limit levels in
electrically conductive liquids with a conductivity of minimum 5µS/cm resp. a resistance of maximum 200k.
The device is also useable as overflow protection in container with liquids, for the realization of a two-position-
control e.g. for pump control or also as dry run protection.
The conductivity also of aggressive filling liquids can be detected, at process temperatures from
-40 °C to +100 °C, at pressures from -1 bar to +10 bar.
The version KAK is the standard type for general applications, whereas the version KLK is especially conceived
for food applications.
The following variants are available:
Relay output version with wide range power supply from 20...253VAC/DC,
for two-channel or s mode with two relay changeover contacts, resp.
Relay output version with wide range power supply from 20...253VAC/DC,
for one-channel or s mode with two relay changeover contacts, resp.
Switching output version with direct voltage power supply 24VDC 10%,
for one-channel or s mode with one PNP switching output.
Function
Measuring principle
The filling level limit switch KAK resp. KLK is mounted in the wall of the container or of the pipe by using the
respective process connection or installed over the filling liquid by using a suitable mount.
The alternating voltage, that is generated by the integrated electronic is than applied either between the
electrode rods or between the electrode rods and the metallic wall of the container resp. pipe that is connected
to the metallic process connection.
Due to the use of a alternating voltage the corrosion at the electrode rod and the electrolytic decomposition of
the filling liquid is avoided.
As soon as the electrically conductive filling liquid makes a connection between the electrodes resp. between
the electrode and the metallic wall of the container resp. pipe, an alternating current flows, that causes a
decrease of the alternating voltage.
Signal evaluation
An evaluation circuit supervises this alternating voltage. A voltage drop is detected and the evaluation circuit
switches the relay resp. relays resp. the PNP switching output, depending on the set safety function.
The switching state of the output resp. outputs is indicated at the top side of the device by two yellow resp. at
the version with PNP switching output by one red LED’s.
Switching delay
In some applications it is necessary to compensate heavy signal fluctuations that may be produced by mixing
machines or at fill-in resp. emptying of containers, to avoid spurious switching actions.
The device is equipped with a switching delay of one second.
This delay time effects both channels separately, at activation and deactivation of the output signals.
Sensitivity range
For the adjustment of the response threshold to the conductivity of the liquid the filling level limit switch can be
adjusted by a multi-turn-trimmer
The detectable resistance is from 0 and 200,0 kresp. 5µS/cm at the relay output version resp. 0 and
100,0 kresp. 10µS/cm at the PNP switching output version.

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Safety function –version UB / UC with relay output
The safety function defines the operation principle of the relays.
Maximum safety: The relay switches off, if the switching level is transgressed,
(liquid connection between measuring and reference electrode REF)
or the power supply fails.
Minimum safety: The relay switches off, if the switching level is underrun,
(no liquid connection between measuring and reference electrode REF)
or the power supply fails.
For both channels, CH1 and CH2, the safety function can be set separately.
This can be carried out by two jumper, one per channel, inside the housing of the device.
Two-position-control s (pump control) –version UB / UC with relay output
The activation of the two-position-control for the output relay S1 is made by a switch inside the device.
The output relay S2* continues operation in limit value mode.
Two-position-control –minimum safety Two-position-control –maximum safety
* The relay S2 is only available at the version UC (wide range power supply with 2x relay output)

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KAK / KLK
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Safety function –version GA with PNP switching output
The safety function defines the operation principle of the PNP switching output.
Maximum safety: The output signal switches off, if the switching level is transgressed,
(liquid connection between electrode CH1 and reference electrode REF)
or the power supply fails.
Minimum safety: The output signal switches off, if the switching level is underrun,
(no liquid connection between electrode CH1 and reference electrode REF)
or the power supply fails.
This respective safety function is set by a jumper inside the housing of the device.
Two-position-control s (pump control) –version GA with PNP switching output
The two-position-control function is always active.
Two-position-control –minimum safety Two-position-control –maximum safety

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Safety notes
Operational safety
The device is safely built and tested according to state-of-the-art technology and has left the factory in perfect
condition as regards technical safety.
The device meets the legal requirements of all relevant EC directives. This is confirmed by attaching the CE
mark.
Installation, connection, commissioning, operation
Installation, electrical connection, commissioning and operation of the device must be made by a qualified and
authorized expert according to the information’s in this technical manual and the relevant standards and rules.
This expert must have read and understood this technical manual and especially the safety notes.
The device may only be used within the permitted operation limits that are listed in this technical manual. Every
use besides these limits as agreed can lead to serious dangers.
The materials of the device must be checked for compatibility with the respective application requirements
(contacting materials, process temperature) before use. An unsuitable material can lead to damage, abnormal
behavior or destruction of the device and to the resulting dangers.
The sensors may not be used as sole device for prevention of dangerous conditions in machines and plants.
Using the device in a manner that does not fall within the scope of its intended use, disregarding this instruction,
using under-qualified personnel, or making unauthorized alterations releases the manufacturer from liability for
any resulting damage. This renders the manufacturer‘s warranty null and void.
Installation
Shortening of the electrode rods
Before the installation into the plant the electrode rods must be shortened acc. to the needed filling level limits.
The numbering that is stamped at the bottom side of the process connection gives an information for the
function of the respective rod.
1-rod-probe 2- rod-probe 2- rod-probe 3- rod-probe
Function
Numbering
Numbering
Numbering
Numbering
CH1
(for s shortest
rod)
1
1
1
1
CH2
(for s longest
rod)
not available
not available
2
2
Reference electrode
REF
(longest rod)
by process
connection thread
2
by process
connection thread
3
The isolation of the electrode rod may not be damaged resp. removed excepted at the electrode tip.
The electrode rods can be shortened arbitrary by a tong or a saw
After shortening the electrode rod remove at least 10 mm of the isolation.
At shortening the electrode may not be stressed mechanically to avoid damaging of the isolation.
1
1
2
1
2
1
2
3

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Installation
Drive the system pressure free prior installation resp. deinstallation of the sensor and avoid high temperatures
to avoid injuries.
Consider enough installation space outside the container or the pipeline to insert the filling level limit switch into
the plant without the use of force.
Install the device if necessary into a bypass if dense heavy foam, wild turbulences or foamed liquids can occur.
Install the filling level limit switch in such a position in the container, where no strong forces to the side, like e.g.
by mixer or near fill-in openings, can have an effect to the electrode rods.
This is especially important for filling level limit switches with especially long electrode rods.
If a metallic wall of a container resp. pipeline should be uses as reference electrode (REF) there must be paid
attention that the metallic process connection of the filling level limit switch is safe electrically conductive
connected with the container resp. the pipeline. Use conductive gaskets like e.g. copper or lead. Isolation
measures like e.g. the wrap of the thread with teflon band or a paper gasket can interrupt the electric contact.
The non-isolated tips of the electrode rods, when mounted, may not make a contact to the wall of the container,
if this is made of metal or electrically conductive plastic.
Electrode rods longer than 0,5 m must be stabilized among each other or against the wall of the container,
especially if the filling liquid is strongly fluctuating.
Use for the stabilization suitable spacers.
The distance between the spaces should be not more than 0,5 m.
At horizontal pipelines the length of the electrodes is limited by that way, that in a
empty pipe, also in the case of liquid residues, the electrically conductive liquid
connection between electrode and wall resp. between the two electrode rods can
disconnect. Otherwise and empty pipe can be detected as filled.
At horizontal side mounting into a container or also into a pipe for stability reasons the
length of the electrode rods should be not more than 200 mm.
At electrode rods with diameter 8 mm the length can be longer.
At a horizontal mounting the electrode rods should be installed at an angel with the
electrode rod tip below (approx. 20...30°), to allow an easier flow-off of filling material
residues and by this to avoid the coat-forming.
The tightening of the process connection may only be done at the hexagon by a suitable spanner.
The maximum permitted torque strength is 50 Nm.
The screw in of the process connection by using the connection housing is not permitted.
Maintenance
The devices is free of maintenance.
The isolation of the electrodes should be checked regularly and also a possible coating at the electrode rods
should be removed.
A non-conductive coating at the metallic electrode tip can effect error behaviour because no current can flow
although the electrically conductive filling liquid makes a connection.
Repair
A repair may only be carried out by the manufacturer.
If the device must be sent back for repair, the following informations must be enclosed:
An exact description of the application.
The chemical and physical characteristics of the product.
A short description of the occurred error.
Before returning the device for repair, the following measures must be proceeded:
All stick product residues must be removed. This is especially important, if the product is unhealthily,
e.g. caustic, toxic, carcinogenic, radioactive etc.
A returning must be refrained, if it is not possible by 100% to remove the unhealthily product
completely, because e.g. it is penetrate into cracks or is diffused through plastic.
NAMUR

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KAK / KLK
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Electrical connection
The electrical connection of the device must be carried out according to the respective country specific
standards. Incorrect installation or adjustment could cause applicationally conditioned risks.
Use only suitable cables with max. 25 per wire, that fulfills the requirements e.g. regarding temperature,
resistance or laying at the place of installation.
The cable gland is suitable for cable diameters from 4 to 10 mm. After installation of the cable the cable gland
must be fix screwed to ensure the tightness of the connection housing.
For inauguration it is suggested to switch off all connected control devices to avoid unintended control actions.
Version UB / UC with relay output
Power supply input, electrode circuit and the two relay outputs are safe galvanically isolated from each other.
Due to the integrated wide range power supply, for connection to supply voltages from 20...253V AC / DC, the
filling level limit switch is suitable for using in all common energy supply networks.
The connection is reverse polarity protected.
A fuse is integrated internally at the power supply circuit. Due to this the installation of a fine protection is not
necessary.
Inductive loads at the relay contacts, e.g. auxiliary contactors or magnetic vents may only be used with a free-
wheeling diode or a RC protection circuit to avoid high voltage peaks.
Version GA with PNP switching output
The power supply voltage and the PNP switching output are galvanically separated from the electrode circuit.
The power supply voltage may not exceed 27 V to avoid damage of the electronic.
The power supply voltage connection is polarity protected.
The load at the PNP switching output will be connected contactless and by this bounce-free to the positive
terminal of the power supply voltage by a semiconductor switch. At activated switching state a positive signal
near power supply voltage is produced at the terminal Out.
At deactivated switching state and at failure of power supply voltage the semiconductor switch is shut off.
The PNP switching output is current limited to 0,5 A.
Inductive loads at the PNP switching output, e.g. relays or contactors may only be used with a free-wheeling
diode or a RC protection circuit to avoid high voltage peaks.
Version UB / UC with relay output Version GA with PNP switching output
terminal occupation terminal occupation plug occupation
* The relay S2 is only available at the version UC (wide range power supply with 2x relay output)
1(brown)
3(blue)
+VS
-VS
Plug M12 x 1
Out
1
2
3
4
4(black)

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Operation and display elements
Type UB / UC –relay output
* The relay S2 only at type UC (2x relay)
Function indicator
LED yellow output relay S1 switched on
LED yellow output relay S2* switched on
Configuration jumper
CH 1 Safety function channel 1 (CH1)
Maximum safety = jumper plugged NO –normally open
Minimum safety = jumper open NC –normally closed
CH 2 Safety function channel 2 (CH2)
Maximum safety = jumper plugged NO –normally open
Minimum safety = jumper open NC –normally closed
s Relay function output relay S1
Limit value function CH1= Jumper open OFF
Two-position control s = Jumper plugged ON
At two-position-control s both jumper for the safety function
channel 1 and channel 2 (CH1 and CH2) must be set identically
Adjustment trimmer
Fine adjustment of the response sensitivity within the sensitivity range.
A turn to the left leads to a switching reaction at the output relays at a higher liquid resistance resp. lower
conductivity.
For adjustment proceed like follows (Safety function –Maximum safety –NO):
Liquid must create an electrically conductive connection between measuring and reference electrode
Turn adjustment trimmer to the right (clockwise), till the output switches off –LED off
Turn adjustment trimmer to the left (counterclockwise), till the output switches on –LED on
Turn adjustment trimmer by an additional half turn to the left (counterclockwise)
Type GA –PNP switching output
Function indicator
LED red PNP switching output active
Configuration jumper
Safety function
Maximum safety = Inv.
Minimum safety = Norm.
Adjustment trimmer
Fine adjustment of the response sensitivity within the sensitivity range.
A turn to the right leads to a switching reaction at the output relays resp. PNP switching output at a higher liquid
resistance resp. lower conductivity.
For adjustment proceed like follows (Safety function –Maximum safety –inv.):
Liquid must create an electrically conductive connection between measuring and reference electrode
Turn adjustment trimmer to the left (counterclockwise), till the output switches off –LED off
Turn adjustment trimmer to the right (clockwise), till the output switches on –LED on
Turn adjustment trimmer by an additional half turn to the right (clockwise)
inv.
+
Vs=22 - 26V DC
PNP-Ausgang
max. 0,5A
Masse
Min.
Max.
norm.
SRAK - 100
Out
1 2 3 4 5 6
LED yellow
output S1
LED yellow
output S2*
Configuration
jumper
Adjustment
trimmer
LED red
output
Adjustment
trimmer
Jumper for
safety function

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KAK / KLK
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Technical data
Auxiliary supply
Version UB / UC with relay output
Supply voltage: 20 V to 253 V AC / DC 48...62 Hz reverse polarity protected
Power consumption: 1,75 VA / 1 W
Overvoltage category: II acc. to DIN EN 61010-1
Protection classification: II double or reinforced insulation
Isolation voltage: 2,5kV~ auxiliary power to relay outputs to electrode circuit
Version GA with PNP switching output
Supply voltage: 24 V DC 10% reverse polarity protected
Ripple voltage: 0,5 VPP condition: within the permitted
supply voltage range
Power consumption: 1 W PNP switching outputs with no load
Overvoltage category: II acc. to DIN EN 61010-1
Protection classification: II double or reinforced insulation
Isolation voltage: 1kV~ auxiliary power / PNP switching output to electrode circuit
Relay output UB / UC
Function: 1x resp. 2x potential-free changeover contact
Switching power of the contacts: 250 Vac / 220 Vdc –2 A –62,5 VA / 60 W (at ohmic load)
100 µV
Delay time: 1 second
Switching cycles: 100.000 at maximum contact load
PNP switching output GA
Function: PNP switching to +Vs
Output voltage: VOUT +Vs–2 V
Output current: 500 mA current limited, short circuit protected
Rise up time: < 30 s
Delay time: 1 second
Switching cycles: 100.000.000
Electrode circuit
Output voltage: potential-free alternating voltage
Output values: 9 VSS 1 V / 90 Hz 15 Hz / 1,5 mA
Measuring range: 200 kresp. 5 µS/cm at version with relay output
100 kresp. 10 µS/cm at version with PNP switching output
Measuring accuracy
Temperature deviation: 0,5% of the measuring range / 10 K

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Technical data
Materials
Electrode rod: Steel 1.4404 (AISI 316L) / 1.4571 (AISI 316Ti) / Hastelloy B4, C22 / Titan
(medium contact)
Electrode isolation: KAK PA / ETFE resp. E-CTFE
(medium contact) KLK ETFE, FDA-listed
Process connection: Steel 1.4404 (AISI 316L) / 1.4571 (AISI 316Ti)
(medium contact)
Terminal enclosure: CrNi-steel + PC / POM + PC / PP + PC / PTFE + PC
Cable gland:
Terminal enclosure CrNi-steel
Enclosure CrNi-steel / Gasket CR, NBR
Terminal enclosure POM / PP / PTFE
Enclosure PA / Gasket CR, NBR
Device plug M12x1: Socket CrNi-steel, insert PUR, contacts gold-plated
Gaskets: medium contact:
KAK
FPM
KLK
EPDM, FDA listed
Others: FPM, silicone
Environmental conditions
Environmental temperature: –40°C...+85°C
Process temperature: –40°C...+100°C
Process pressure range: –1 bar ...10 bar
Weight: Terminal enclosure steel 0,5 kg
Terminal enclosure PTFE / POM / PP 0,2 kg
Electrode rod diameter 4 mm 0,1 kg / 1000 mm
Electrode rod diameter 8 mm 0,4 kg / 1000 mm
Torque strength: 80 Nm
Protection classification: IP65 DIN EN 60529
EM –compatibility: Emission DIN EN 61326-1 operation device class B
Immunity DIN EN 61326-1 industrial range
Operation
Indication limit value: 1 resp. 2 LED, yellow at version UB / UC with relay output
1 LED, red at version GA with PNP switching output
Configuration: 3 jumper at version UB / UC with relay output
1 jumper at version GA with PNP switching output
Sensitivity adjustment: 1 trimmer 12-turn at version UB / UC with relay output
1 trimmer 20-turn at version GA with PNP switching output
Connection terminals
Version UB / UC with relay output
Number: 8 terminals, everlasting screws
Connection cross-section: maximum 1x 1,5 mm2rigid / flexible
Version GA with PNP switching output
Number: 3 terminals, everlasting screws
Connection cross-section: maximum 1x 2,5 mm2rigid / flexible

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KAK / KLK
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Dimension drawing KAK
KAK –_ _1G12_ _ _ _
KAK –_ _2G10_ _ _ _
KAK –_ _3G15_ _ _ _

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Dimension drawing KLK
KLK –_ _2G10_ _ _ _
KLK –_ _1G12_ _ _ _
KLK –_ _3G15_ _ _ _

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Dimension drawing KLK
KLK –_ _2D40_ _ _ _
KLK –_ _1D25_ _ _ _
KLK –_ _3D50_ _ _ _

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BEFC-62 for KLK DN25 BEFB-62 for KLK DN40 BEFA-62 for KLK DN50
acc. to DIN 11851 acc. to DIN 11851 acc. to DIN 11851
SEM12 for KLK G1/2“ SEM10 for KLK G1“ SEM15 for KLK G 1½“
Dimension drawing welding sleeves

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Type
KAK Standard
KLK Food applications
Electrical connection
0 Terminal box
V Plug M12 x 1 only at auxiliary power direct voltage 24 V DC
Auxiliary power
G Direct voltage 24 V DC
U Wide range power supply 20...253 V AC/DC
Output
A 1 x PNP switching output only at auxiliary power direct voltage 24 V DC
B 1 x relay output only at auxiliary power wide range power supply 20...253 V AC/DC
C 2 x relay output only at auxiliary power wide range power supply 20...253 V AC/DC
Type measuring system
1 1-rod 1x limit value Reference electrode REF –process connection
2 2- rod 1x limit value Reference electrode REF –longest rod
3 3- rod 2x limit value Reference electrode REF –longest rod
4 2- rod 2x limit value Reference electrode REF –process connection
Process connection material CrNi-steel (medium contact)
G12 Thread ISO 228-1 –G ½“ – 1-rod
G10 Thread ISO 228-1 –G 1“ – 2-rod
G15 Thread ISO 228-1 –G 1½“ – 3-rod
D25 Dairy coupling DIN 11851 –DN25, 1-rod only type KLK
D40 Dairy coupling DIN 11851 –DN40, 2-rod only type KLK
D50 Dairy coupling DIN 11851 –DN50, 3-rod only type KLK
YYY others on request
Material electrode rod (medium contact)
A4 CrNi-steel, rod diameter 4 mm
A8 CrNi-steel, rod diameter 8 mm
C Hastelloy B4, rod diameter 4 mm
D Hastelloy C22, rod diameter 4 mm
T4 Titan, rod diameter 4 mm
T8 Titan, rod diameter 8 mm
E CrNi-steel, tip tantalum 50mm, on request
Y others on request
Material terminal enclosure
D POM
P PP
L PTFE
V CrNi-steel
Material electrode isolation (medium contact)
R PA only type KAK
H4 ETFE (KLK) resp. E-CTFE, rod diameter 4 mm
H8 ETFE (KLK) resp. E-CTFE, rod diameter 8mm
Diameter electrode rod
0 4 mm
W 8 mm
Length L1/L2/L3 electrode rod in mm, max. 2500 mm
KAK resp. KLK __________
Order code overview