Baumer CleverLevel LFFS Series User manual

www.baumer.com Operating instructions: 11109132 07 EN Page 1 / 12
Safety instructions
2017-06-08 Design and specifications subject to change without notice
This instrument is constructed and tested according to the current EU-
directives and packed in 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 opera-
tion of this equipment is dependent on proper transport, storage, instal-
lation 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 designed to detect levels in tanks, 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. A 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, yoghurt, tooth-
paste and ketchup. Even dry medias can be measured, e.g. sugar or flour.
The Level Switch LFFS is resistant against CIP and SIP agents.
Hygienic installation is also possible with the comprehensive range of accessories, see the overview at page 6.
WARNING
When the top cover is removed, do not look directly at the blue LED with unshielded eyes or damage to retina may occur !
This product contains no replaceable parts. In case of malfunction the product must be shipped to Baumer for repair.
Operating instructions
CleverLevel switch, LFFS
CleverLevel switch, type LFFS is an universal level switch, which
can be used for all applications in liquids and solids with a DC-value
above 1.5

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Measuring principle
Mounting
Operating instructions
CleverLevel switch, LFFS
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 com-
bination with a coil in the sensor head. Switching signal tripping is
according to the measured resonance frequency and the programmed
trigger thresholds.
Please refer to “Accessories” data sheet. The welding part has
an engraved mark or a leak hole. When the product has been
mounted and correctly tightened the gland or M12 plug will
align with this mark.
Make sure that the gland/plug is pointing downwards to pre-
vent fluids from penetrating into the instrument.
Use only the authorised special designed accessories. The
product warranty is void when installed with other adapters.
Do not use PTFE, fibre or other gaskets. The PEEK tip against
the stainless steel welding part will perform a hygienic tighten-
ing 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.
Dimensions
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.
The Level Switch LFFS with sliding connection can be mounted
in installations with a static pressure up to 16 bar.
To prevent personal injuries or property damage it is essential
that the safety wire is mounted correctly and is undamaged.
WARNING
100
or
250
Sliding
connection
G½
2 × PEEK
sealing
washers
Spare part set:
ZPX1-006
Safety
wire
G½ hygienic 3A DN38 hygienic G½ hygienic sliding connection
19,0
31,5
14,5

Operating instructions
CleverLevel switch, LFFS
Mounting
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NOTE
The M12 cable rotating nut must be tightened by hand force only.
Max. torque is 0.6 Nm. Do not use any tool.
Refer to the data sheet “Accessories” for O-rings, gaskets and other
accessories.
If the PEEK sealing rings for sliding connection is damaged or seri-
ously scratched, the instrument or sealing rings should be replaced
(type ZPX1-006).
1) Use only a 3-A approved counterpart.
2) The leak detection port should be visible and drained.
After installation:
 Check the leak tightness of the sleeve.
 Check the tightness of cable glands or M12 plug.
Example
with ZPW2-626



Example with
ZPW2-321
Example
with ZPW2-621
 Leak detection port
must be placed at the
lowest possible position.
Fitted
Cannot be
drained
WARNING
5) The 3-A mark or the arrow shall be placed upwards.
6) Welding should be grinded to Ra ≤ 0.8.
7) Tighten the instrument in the adapter with a torque of 15...20 Nm.
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 sanitising liquid. Use a small brush. Verify that all of
the inside area is completely clean.
Reassemble and verify that the connection is tight.
The industrial versions with thread must be sealed e. g. by gasket or
Teflon® tape and tightened into the counterpart.
Installation of hygienic 3-A approved and EHEDG certified products,
please refer to below:
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.
Stainless
steel tube
NOTE
The CleverLevel switch is to be mounted in a closed metal pipe, tank
or container.

Refer to data sheet ”Accessories Universal” for further
information
NOTE:
The LFFS must be mounted in a Baumer mounting
connection.
If not, Baumer do not guarantee correct function or
tightness.
Operating instructions
CleverLevel switch, LFFS
Mounting connections
ISO2852 SMS 1145 Welding
DN38: ZPH1-3213 DN51: ZPH1-3236 for tank
DN51: ZPH1-3216 ZPW2-321
Varivent®, type N DIN 11851 Welding
ZPH1-324E DN25: ZPH1-3221 for tank
DN40: ZPH1-3224 ZPW2-322
DN50: ZPH1-3225
DIN 11864-1/A Welding Ø35
DN 40: ZPH1-3254 for tank/tube
DN 50: ZPH1-3255 ZPW2-324
Adapter Welding
EH FTL to pipe extrusion
G¾A: ZPH1-32BA DN 25...DN50: ZPW2-326
G1A: ZPH1-32CB DN 65...DN150: ZPW2-327
VS
G¾A: ZPH1-32BC
G1A: ZPH1-32CD
Adapter Adapter, industrial Adapter, industrial
G½ → G1 G½ → G1: ZPI1-32B Sliding connection
ZPH1-32C0 G½ → G1½: ZPI1-32D G½ → G½: ZPI1-32A
G½ → G2: ZPI1-32E
Welding
for tank
ZPW2-621
Welding
for pipe end
ZPW2-626
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On a welding adapter there is an
arrow or a 3A logo.
This must be placed upwards when
welding the adapter into a tank
(horizontal position).
This assures that the electrical con-
nection will be pointing downwards
(opposite of the arrow; 3A logo)

Media temperature and external length for sliding connection
Operating instructions
CleverLevel switch, LFFS
Media temperature °C
120
115
110
105
100
95
90
85
80
75
50 55 60 65 70 75 80 85 90
Ambient temperature °C
LFFS-xx1.x / LFFS-xx2.x LFFS-xx3.x and LFFS-xx4.x
External length of sliding connection
Media temperature °C
External length
See example
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
ATEX data.
Example, how to read 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 in-
sertion 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.
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For CIP/SIP Media temperature, max. 140°C
Ambient temperature, max. 60°C
Duration, max. 1 hour
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 was changed from standard factory settings, it is necessary to re-adjust the new switch to 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 an very exact set point is required, a new
teach-in or adjustment by the FlexProgram must be performed.

Operating instructions
CleverLevel switch, LFFS
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.
Press  or  to browse the menus
 to access current menu point
 to return to previous menu
 and  simultaneously to reset FlexProgrammer
and go in sleep mode
Teach-In
Press
 and  simultaneously
Select Menu “Teach-In”
 Search for product
= Product LFS/LBFS
 At 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.
Step To do LED Result
1Connect terminal ”Teach-In” to
- VDC (T1 or T2) for 3,5 second Flash 1 time per second Ready for Teach-in
2With no media present connect
”Teach-In” to - VDC shortly Light on for 2 second and then flash Register ”empty” state. Pls. See note
3With media present connect
”Teach-In” to - VDC shortly Light on for 2 seconds Register ”full” state, stores the value and returns to Normal operation with 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 estab-
lished also during the Teach-In process. Otherwise a faulty calibration can be the result.
If Teach-In for some reason do 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 settings will be confirmed by pulsing light intensity 3 times.
Error state description LED Result
Error state Blinking, 3 × short and 1 × long Can normally be fixed by powering off and on and remake the Teach-In.
Alternatively remake the Teach-In configuration by use of the FlexPro-
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 LFFS / 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%
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Electrical connection
Operating instructions
CleverLevel switch, LFFS
M12 plug: 1 Brown
2 White*
3 Blue
4 Black
*To avoid unintended Teach-In, be aware not to
connect the Teach-In pin or expose it to any
electrical noise during normal operation.
Normally open - NO
Normally closed - NC
Electrical specifications:
Power supply 12,5...36 VDC, 35 mA max.
Output PNP, NPN or Digital
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
1
2
5
1
2
5
1
2
5
1
2
5
1
2
5
1
2
5
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ATEX
Operating instructions
CleverLevel switch, LFFS
Ex ia IIC T5, ATEX II 1G - Installation
A Level Switch LFFS-1xx.x is Ex ia IIC T5, ATEX II 1G ap-
proved 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 with a barrier
Ex-data
Supply range 24...30 VDC
Temperature class T1...T5 Pls. see above table
Internal inductivity Li<10 µH
Internal capacity Ci<33 nF
Barrier data U <30 VDC
I <0.1 A
P <0.75 W
Connection type Ambient temperature Media temperature
(max. allowed)
Note
G½ hygienic -40 … +85 °C +85 °C
3A DN38 -40 … +60 °C +95 °C 1)
-40 … +40 °C +115 °C 1)
100 mm -40 … +85 °C +85 °C
Sliding connection -40 … +60 °C +155 °C 1)
-40 … +40 °C +175 °C 1)
250 mm -40 … +85 °C +85 °C
Sliding connection -40 … +60 °C +195 °C 1)
-40 … +40 °C +200 °C 1)
Conditions for Ex certification
1) Provided that
the sensor tip
at the instru-
ment is the
only part in
contact with
the media
ATEX Gas ia
LFFS-1xx.x
with PNP output
Safe area
+22...120 VDC
or
- 90...253 VAC
Note:
For PNP output the barrier module
PFOFSI3-B25100-ALG-LS
is required for functional purposes.
PFOFSI3-B25100-ALG-LS
NPN out
LFFS-1xx.x
with NPN output
Note:
For NPN output only!
A standard barrier may be used
Standard barrier
Two-channel
ZENER barrier
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Note:
There is an electrical connection between intrinsic safe circuit
and housing due to the measurement principle

ATEX Dust tD
Operating instructions
CleverLevel switch, LFFS
ATEX Gas nA
Ex-Configuring
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 for zone 20 without a barrier.
Ex-data
Supply range VDC 12,5...30
Load I<0.1 A
Temperature class T1...T5 Pls. see table top page 8
12,5...30 VDC
1
2
5
A Level Switch LFFS-3xx.x is Ex nA II 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
Supply range VDC 12,5...30
Load I<0.1 A
Temperature class T1...T5 Pls. see table top page 8
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.
f) Connect the power supply to the circuit.
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12,5...30 VDC
1
2
5
Outside hazardous area

WHG leakage approval / overfill approval
Operating instructions
CleverLevel switch, LFFS
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Operating instructions
CleverLevel switch, LFFS
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WHG leakage and overfill protection approval

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For further information please refer to www.baumer.com