Bühler technologies NS 1-G1-AM Owner's manual

Fluidcontrol
Installation and Operation Instructions
Original instructions
External level switches
NS 1-G1/2-AM
BE200006
01/2022
Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen
Tel. [phone] / 49 89-0, Fax: [phone] / 49 89-20
E-Mail: [email protected]
Internet: www.buehler-technologies.com

Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen
Tel. [phone] / 49 89-0, Fax: [phone] / 49 89-20
Internet: www.buehler-technologies.com
E-Mail: [email protected]
Read this instruction carefully prior to installation and/or use. Pay at-
tention particularly to all advises and safety instructions to prevent in-
juries. Bühler Technologies can not be held responsible for misusing
the product or unreliable function due to unauthorised modifications.
All rights reserved. Bühler Technologies GmbH 2022
Document information
Document No.........................................................BE200006
Version......................................................................... 01/2022

NS 1-G1/2-AM
Contents
1 Introduction..................................................................................................................................................................................................................... 2
1.1 Intended Use.........................................................................................................................................................................................................2
1.2 Functionality......................................................................................................................................................................................................... 2
1.3 Model key............................................................................................................................................................................................................... 2
1.4 Scope of Delivery.................................................................................................................................................................................................. 2
2 Safety instructions......................................................................................................................................................................................................... 3
2.1 Important advice................................................................................................................................................................................................. 3
2.2 General hazard warnings .................................................................................................................................................................................4
3 Transport and storage .................................................................................................................................................................................................. 5
4 Installation and connection ........................................................................................................................................................................................6
4.1 Mechanical installation.....................................................................................................................................................................................6
4.2 Electrical connections ........................................................................................................................................................................................ 7
4.3 Adjusting the level contacts............................................................................................................................................................................. 7
4.4 Information on the correct operation of reed contacts in Bühler level switches.............................................................................9
5 Operation and control ................................................................................................................................................................................................ 10
6 Cleaning and Maintenance........................................................................................................................................................................................ 11
7 Service and repair..........................................................................................................................................................................................................12
8 Disposal............................................................................................................................................................................................................................13
9 Appendices..................................................................................................................................................................................................................... 14
9.1 Technical Data.................................................................................................................................................................................................... 14
9.2 Standard pin assignment ................................................................................................................................................................................15
10 Attached documents................................................................................................................................................................................................... 16
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1 Introduction
1.1 Intended Use
The NS1 level switch series serves liquid level monitoring in tanks in fluid systems. They are installed on the tank and have a
visual display. Up to four switching contacts provide an electronic signal for fill level monitoring.
A medium temperature between -20 °C and 80 °C (-4 °F and 176 °C) must be maintained. The level switch must not be used in
highly flammable or corrosive liquids. The medium must not contain particles, particularly metallic particles, to prevent depos-
its on the float or between the float and switching tube. If necessary, filter the medium.
Please refer to the technical data for the specific intended use and available material combinations.
Please refer to the type plate for your equipment configuration. In addition to the job number, this also contains the item num-
ber and type designation.
WARNING
All device models are solely intended for industrial applications. They are not safety com-
ponents. The devices must not be used if failure or malfunction thereof jeopardises the
safety and health of persons.
Use in explosive areas is prohibited.
Any use outside the technical data and outside the areas of application specified in these instructions is considered improper
use.
1.2 Functionality
The measuring tube is located inside the bypass tank with sight glass. The level switches are located inside the measuring tube.
These are activated by a magnet inside the level switch float.
The level contacts are reed switches. They are mounted to a perforated rail spaced as specified in the purchase order, but can be
moved.
1.3 Model key
NS 1-G1/2-AM-xx-nn-xx-xx
M3
M12
C7
NO/NC
Changeover (max. 2)
K
W
280
370
500
nnn
Type designation
Plug connection
Length
1- 4 contacts
Level measurement
Level contacts
Connection
G1/2
Tank top installation
(variable, please specify value)
Ordering example:
You require: Level switch for external installation, G1/2 connections, length L= 370 mm, M3 plug connection
2 level contacts, 1st contact 100 mm NC, 2nd contact 300 mm NO
Order NS 1-G1/2-AM-M3/370-2K L1=100 NC, L2 = 300 NO
1.4 Scope of Delivery
– Level switch
– Product documentation
– Connection/mounting accessories (optional)
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2 Safety instructions
2.1 Important advice
Operation of the device is only permitted if:
– the product is used under the conditions described in the installation- and operation instruction, the intended application
according to the type plate and the intended use. In case of unauthorized modifications done by the user Bühler Technolo-
gies GmbH can not be held responsible for any damage,
– when complying with the specifications and markings on the nameplates.
– the performance limits given in the datasheets and in the installation- and operation instruction are obeyed,
– monitoring devices and safety devices are installed properly,
– service and repair is carried out by Bühler Technologies GmbH,
– only original spare parts are used.
This manual is part of the equipment. The manufacturer keeps the right to modify specifications without advanced notice. Keep
this manual for later use.
Signal words for warnings
DANGER
Signal word for an imminent danger with high risk, resulting in severe injuries or death if not avoided.
WARNING
Signal word for a hazardous situation with medium risk, possibly resulting in severe injuries or death if not
avoided.
CAUTION
Signal word for a hazardous situation with low risk, resulting in damaged to the device or the property or
minor or medium injuries if not avoided.
NOTICE
Signal word for important information to the product.
Warning signs
These instructions use the following warning signs:
Warns of a general hazard General notice
Warns of voltage Unplug from mains
Warns not to inhale toxic gasses Wear respiratory equipment
Warns of corrosive liquids Wear a safety mask
Warns of explosive areas Wear gloves
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2.2 General hazard warnings
The equipment must be installed by a professional familiar with the safety requirements and risks.
Be sure to observe the safety regulations and generally applicable rules of technology relevant for the installation site. Prevent
malfunctions and avoid personal injuries and property damage.
The operator of the system must ensure:
– Safety notices and operating instructions are available and observed,
– The respective national accident prevention regulations are observed,
– The permissible data and operational conditions are maintained,
– Safety guards are used and mandatory maintenance is performed,
– Legal regulations are observed during disposal,
– compliance with national installation regulations.
Maintenance, Repair
Please note during maintenance and repairs:
– Repairs to the unit must be performed by Bühler authorised personnel.
– Only perform conversion-, maintenance or installation work described in these operating and installation instructions.
– Always use genuine spare parts.
– Do not install damaged or defective spare part. If necessary, visually inspect prior to installation to determine any obvious
damage to the spare parts.
Always observe the applicable safety and operating regulations in the respective country of use when performing any type of
maintenance.
The method for cleaning the devices must be adapted to the IP protection class of the devices. Do not use cleaners which could
damage the device materials.
DANGER Toxic, corrosive gases or liquids
Gasses or liquids can be harmful to the health.
a) If necessary, ensure a safe gas/liquid discharge.
b) Always disconnect the gas supply when performing maintenance or repairs.
c) Protect yourself from toxic/corrosive gasses/liquids when performing maintenance.
Wear suitable protective equipment.
DANGER Potentially explosive atmosphere
Explosion hazard if used in hazardous areas.
The device is not suitable for operation in hazardous areas with potentially explosive at-
mospheres.
Do not expose the device to combustible or explosive gas mixtures.
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3 Transport and storage
Only transport the product inside the original packaging or a suitable alternative.
The equipment must be protected from moisture and heat when not in use. It must be stored in a covered, dry, dust-free room
at room temperature.
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4 Installation and connection
4.1 Mechanical installation
CAUTION Oil leak
Damaged sight glass
Ensure the bypass tank, particularly the sight glass, is not damaged by external forces.
NOTICE
The level switch must be mounted vertically to the tank to allow the float to move freely.
The mounting surface on the tank must have a minimum surface quality of Rmax = 6.3. If
the surface quality is inadequate, leaks may occur.
The level switches come fully assembled and can be mounted to the tank with G1/2 hollow screws.
Proceed as follows:
– Install the bypass tank (1) in the planned position:
Ensure the O-rings (4) are correctly seated in the grooves on the bypass tank.
– Insert the two G1/2 hollow screws (2) all the way through the respective G3/4 opening and firmly secure to the tank.
– The screw the two VSTI plugs (3) firmly into the G3/4 threads on the tank.
1 Bypass tank 2 G1/2 hollow screws
3 VSTI plugs 4 O-rings
5 Mounting surface (note surface quality) 6 Hexagon nut SW36
7 Spanner size SW12 8 Magnet
9 Float
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CAUTION Oil leak
Removing the level switch
When removing the level switch, ensure there is no fluid left in the tank or could leak
from the tank.
Note: After removing the float, be sure the magnet inside the float is above the fluid level. This can easily be verified with a piece
of iron to determine the magnet position inside the float.
4.2 Electrical connections
For devices with 230 V mains voltage:
DANGER Electrical voltage
Electrocution hazard.
a) Disconnect the device from power supply.
b) Make sure that the equipment cannot be reconnected to mains unintentionally.
c) The device must be opened by trained staff only.
d) Regard correct mains voltage.
The connection voltage is 24VDC or 230VAC (rated values). It connects with plugs. Please refer to the drawing in the appendix
for the pin assignment.
Depending on the order specifications, the level contacts are "falling NO contact (NC)", "falling NC contact (NO)" (contact type K8)
or changeover contacts (contact type W9) and mounted in the specified position. The position can be changed later (see chapter
Adjusting the level contacts [> page7]). The contact logic assumes the level switch is installed with the tank empty, meaning
it is only in the operating position once the tank has been filled.
4.3 Adjusting the level contacts
The contacts for level measurement are locked into a bent rail inside the protective tube. They are positioned as specified in the
purchase order, but can be moved to any position if necessary.
For devices with 230 V mains voltage:
DANGER Electrical voltage
Electrocution hazard.
a) Disconnect the device from power supply.
b) Make sure that the equipment cannot be reconnected to mains unintentionally.
c) The device must be opened by trained staff only.
d) Regard correct mains voltage.
– Disconnect the voltage supply.
– Disconnect the plug.
– Unscrew the plug base. For plug-in connectors with screw-in plug base, unscrew the top hexagon ring and pull the complete
pin insert up until the bottom of the base can be unscrewed freely.
– Carefully pull the bent rail with contacts out the top.
NOTICE
The earth wire is a loop and soldered to the protective tube from the inside in the inser-
tion direction. To prevent breaking off the earth wire it should not be pulled all the way
out.
– Mark the original contact position.
NOTICE
Never attempt to remove the contacts from the front of the bent rail, as this will damage
the glass body. Do not pull on the cables.
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– Carefully slide the contacts to the desired position on the bent rail. Use a small screwdriver or similar tool to do so. Use a drop
of oil if the contacts are very tight. Please note the minimum spacing!
If the contacts are configured as NO contact (NO) or NC contact (NC), the contact function can be reversed by turning the con-
tacts 180°. There is a red mark on the housing indicating the "NO contact" function. The contact logic assumes the level switch is
installed in an empty tank, i.e. it is only in the operating position once filled.
NO contact function
with rising level (NO)
NC contact function
with rising level (NC)
Red marking down
Red marking up
– To reverse the switching function, slide the contact out the top or bottom of the bent rail, turn 180° and slide back in, and
slide into the desired position.
– If the earth wire was pulled out of the protective tube, first insert this wire into the protective tube.
– Make a loop of the additional cable length and carefully slide the bent rail back in.
– Screw on the plug base. For plugs with screw-in thread, attach the plug base clean and screw in hand tight. Leave the pin in-
sert free so the base can turn around the cables. Now slide the cables all the way in, lock the pin insert into the guide and
slide all the way in. Tighten the top hexagon ring hand tight.
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4.4 Information on the correct operation of reed contacts in Bühler level switches
Based on their construction, reed contacts are very long lasting and reliable components. Yet the following should be considered
when using them:
Life of reed switches
The life of reed switches can be up to 109 cycles. This is reduces by high stress and / or incorrect or the absence of protective cir-
cuits when switching inductive, capacitive or lamp loads.
It’s therefore important to ensure NEVER to exceed one or several of the maximum approved limits, even temporarily, and to
install a contact protective circuit for loads which are not purely ohmic. Using test lamps when installing the devices is also pro-
hibited, as these can temporarily allow too much current to flow, which can damage the reed contacts. In this case non-volatile
testing equipment should always be used.
Contact protective circuits for reed switches
For direct current voltage a recovery diode per figure A must be connected parallel to the contact.
For alternating current voltage an RC circuit per Figure B and Table 1 must be connected parallel to the contact.
A B
Load
Contact
Recovery diode
Load
Contact
RC circuit
Load in VA 10 25 50
Voltage at contact V R/Ohm C/µF R/Ohm C/µF R/Ohm C/µF
24 22 0.022 1 0.1 1 0.47
60 120 0.0047 22 0.022 1 0.1
110 470 0.001 120 0.0047 22 0.022
230 470 0.001 470 0.001 120 0.0047
Please note the max. voltage/load ratings of the respective level contacts!
Voltages and currents
All Bühler level contacts with reed switch can switch minimal Switching voltages of 10µV and minimal switching currents of
1µA.
The maximum values specified for the respective contact types apply.
Level contact with reed switches can therefore be used for SPS applications as well as for high loads (within the maximum lim-
its) without hesitation.
Contact material
All reed switches in Bühler level contacts use rhodium as the contact material for the actual contact areas.
Magnetic fields
Avoid external magnetic fields, including from electric motors. These can interfere with the function of the reed switches.
Mechanical loads
Do not expose the level switch to strong blows or bending.
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5 Operation and control
NOTICE
The device must not be operated beyond its specifications.
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6 Cleaning and Maintenance
DANGER Toxic, corrosive gases or liquids
Gasses or liquids can be harmful to the health.
a) If necessary, ensure a safe gas/liquid discharge.
b) Always disconnect the gas supply when performing maintenance or repairs.
c) Protect yourself from toxic/corrosive gasses/liquids when performing maintenance.
Wear suitable protective equipment.
During maintenance, remember:
– The equipment must be maintained by a professional familiar with the safety requirements and risks.
– Only perform maintenance work described in these operating and installation instructions.
– When performing maintenance of any type, observe the respective safety and operation regulations.
– The method for cleaning the devices must be adapted to the IP protection class of the devices. Do not use cleaners which
could damage the device materials.
Regularly check the bypass valve and remove any deposits to keep the float clear. Clean the sight glass as necessary.
No other maintenance required.
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7 Service and repair
This chapter contains information on troubleshooting and correction should an error occur during operation.
Repairs to the unit must be performed by Bühler authorised personnel.
Please contact our Service Department with any questions:
Tel.: [phone] or your agent
If the equipment is not functioning properly after correcting any malfunctions and switching on the power, it must be inspected
by the manufacturer. Please send the equipment inside suitable packaging to:
Bühler Technologies GmbH
- Reparatur/Service -
Harkortstraße 29
40880 Ratingen
Germany
Please also attach the completed and signed RMA decontamination statement to the packaging. We will otherwise be unable to
process your repair order.
You will find the form in the appendix of these instructions, or simply request it by e-mail:
[email protected].
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8 Disposal
Dispose of parts so as not to endanger the health or environment. Follow the laws in the country of use for disposing of elec-
tronic components and devices during disposal.
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9 Appendices
9.1 Technical Data
Basic Unit Dimensions
Operating pressure: max. 1 bar
Plug
G3/4
SW12
27Display = L-54
min. 70
Hex SW12
O-ring gasket
32 62
L1 = min. 50
Sight glass
Ø40
SW 36
first
contact
last
contact
32
Plug
G3/4
SW12
L2 = min. 90
L
50
G1/2
58
Installation end
16
Required surface quality
for the opposite
mounting surface
Operating temperature: -20 °C to +80 °C
Min. fluid density: 0.80 kg/dm³
Lengths: 280, 370, 500 mm (standard)
variable to max. 800 mm
Weight at L = 280 mm: approx. 2.75 kg
Extra per 100 mm: approx. 0.25 kg
Material
Housing: Anodised aluminium
Sight glass: Plexiglas (PMMA)
Fixing screws: Chromated steel
Seal: NBR
Level switch Brass
Float: NBR
Level contacts K8 W9
Function: NO/NC* Changeover
contact
Max. operating voltage: 230 V 48 V
Max. switching current: 0.5 A 0.5 A
Max. contact load: 10 VA 20 VA
Min. contact spacing: 40 mm 40 mm
*NO= falling NC contact/NC = falling NO contact
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9.2 Standard pin assignment
Connector: M3 valve connector M12 plug A-coded C7 HAN 3 A
Dimensions:
38
M12x1
Connection schematic:
3
12
PE
1
3
5
4
67
8 (PE)
2
Number of poles: 3-pin + PE 4-pin 7-pin + PE
DIN EN 175301-803 61076-2-101 175301-801
Max. voltage: 230 V AC/DC* 30 V DC 230 V AC/DC*
IP rating: IP65 IP67** IP65***
Cable fitting: PG 11 PG 11
Max. Number of level contacts: 2 x K8
1 x W9
2 x K8
1 x W9
4 x K8
3 x W9
K8
Level contact(s)
W9
Level contact(s)
*Max. 48 V AC/DC for change-over contact. **IP67 with cable box attached. ***IP44 with gland/without gasket.
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10 Attached documents
– Declaration of Conformity KX100008
– RMA - Decontamination Statement
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RMA-Nr./ RMA-No.
Die RMA-Nummer bekommen Sie von Ihrem Ansprechpartner im Vertrieb oder Service./ You may obtain the RMA
number from your sales or service representative.
Firma/ Company
Firma/ Company
Straße/ Street
PLZ, Ort/ Zip, City
Land/ Country
Zu diesem Rücksendeschein gehört eine Dekontaminierungserklärung. Die gesetzlichen Vorschriften schreiben vor,
dass Sie uns diese Dekontaminierungserklärung ausgefüllt und unterschrieben zurücksenden müssen. Bitte füllen Sie
auch diese im Sinne der Gesundheit unserer Mitarbeiter vollständig aus./ This return form includes a decontamination
statement. The law requires you to submit this completed and signed decontamination statement to us. Please com-
plete the entire form, also in the interest of our employee health.
Ansprechpartner/ Person in charge
Name/ Name
Abt./ Dept.
Tel./ Phone
E-Mail
Gerät/ Device
Anzahl/ Quantity
Auftragsnr./ Order No.
Serien-Nr./ Serial No.
Artikel-Nr./ Item No.
Grund der Rücksendung/ Reason for return
Kalibrierung/ Calibration Modifikation/ Modification
Reklamation/ Claim Reparatur/ Repair
andere/ other
bitte spezifizieren/ please specify
Ist das Gerät möglicherweise kontaminiert?/ Could the equipment be contaminated?
Nein, da das Gerät nicht mit gesundheitsgefährdenden Stoffen betrieben wurde./ No, because the device was not operated with
hazardous substances.
Nein, da das Gerät ordnungsgemäß gereinigt und dekontaminiert wurde./ No, because the device has been properly cleaned and
decontaminated.
Ja, kontaminiert mit:/ Yes, contaminated with:
explosiv/
explosive
entzündlich/
flammable
brandfördernd/
oxidizing
komprimierte
Gase/
compressed
gases
ätzend/
caustic
giftig,
Lebensgefahr/
poisonous, risk
of death
gesundheitsge-
fährdend/
harmful to
health
gesund-
heitsschädlich/
health hazard
umweltge-
fährdend/
environmental
hazard
Bitte Sicherheitsdatenblatt beilegen!/ Please enclose safety data sheet!
Das Gerät wurde gespült mit:/ The equipment was purged with:
Diese Erklärung wurde korrekt und vollständig ausgefüllt und von einer
dazu befugten Person unterschrieben. Der Versand der (dekontaminier-
ten) Geräte und Komponenten erfolgt gemäß den gesetzlichen Bestim-
mungen.
This declaration has been filled out correctly and completely, and signed by
an authorized person. The dispatch of the (decontaminated) devices and
components takes place according to the legal regulations.
Datum/ Date
rechtsverbindliche Unterschrift/ Legally binding signature
Falls die Ware nicht gereinigt, also kontaminiert bei uns eintrifft, muss die
Firma Bühler sich vorbehalten, diese durch einen externen Dienstleister
reinigen zu lassen und Ihnen dies in Rechnung zu stellen.
Should the goods not arrive clean, but contaminated, Bühler reserves the
right, to comission an external service provider to clean the goods and in-
voice it to your account.
Firmenstempel/ Company Sign
DE000011
01/2019
RMA-Formular und Erklärung über Dekontaminierung
RMA-Form and explanation for decontamination
Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen
Tel. [phone] / 49 89-0, Fax: [phone] / 49 89-20
E-Mail: [email protected]
Internet: www.buehler-technologies.com