Burkert 558129 User manual

Operating Instructions
LEVEL SWITCH 8112
with transistor output

Contents
1About this document
1.1Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3Symbolism used. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2For your safety
2.1Authorised personnel . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2Appropriate use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3Warning about misuse . . . . . . . . . . . . . . . . . . . . . . . 5
2.4General safety instructions . . . . . . . . . . . . . . . . . . . . 5
2.5Safety label on the instrument . . . . . . . . . . . . . . . . . . 6
2.6CE conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.7SIL conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.8Safety instructions for Ex areas . . . . . . . . . . . . . . . . . 6
3Product description
3.1Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2Principle of operation . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.4Storage and transport . . . . . . . . . . . . . . . . . . . . . . . . 9
4Mounting
4.1General instructions . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.2Instructions for installation . . . . . . . . . . . . . . . . . . . . . 13
5Connecting to power supply
5.1Preparing the connection . . . . . . . . . . . . . . . . . . . . . 17
5.2Connection procedure. . . . . . . . . . . . . . . . . . . . . . . . 17
5.3Wiring plan,single chamber housing . . . . . . . . . . . . . 18
6Set up
6.1General information . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.2Adjustment elements . . . . . . . . . . . . . . . . . . . . . . . . 20
6.3Function chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7Maintenance and fault rectification
7.1Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.2Remove interferences. . . . . . . . . . . . . . . . . . . . . . . . 23
7.3Exchange of the electronics . . . . . . . . . . . . . . . . . . . 24
8Dismounting
8.1Dismounting steps . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8.2Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9Supplement
9.1Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9.2Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2LEVEL SWITCH 8112 •with transistor output
Contents
32051-EN-120418

Supplementary documentation
Information:
Supplementary documents appropriate to the ordered version come
with the delivery.You can find them listed in chapter "Product
description".
Instructions manuals for accessories and replacement parts
Tip:
To ensure reliable setup and operation of your LEVEL SWITCH 8112,
we offer accessories and replacement parts.The corresponding
documentations are:
lOperating instructions manual "Oscillator LEVEL SWITCH 8111/
8112"
lOperating instructions manual "Lock fitting for LEVEL SWITCH
8112"
Editing status:2012-04-12
LEVEL SWITCH 8112 •with transistor output 3
Contents
32051-EN-120418

1About this document
1.1Function
This operating instructions manual provides all the information you
need for mounting,connection and setup as well as important
instructions for maintenance and fault rectification.Please read this
information before putting the instrument into operation and keep this
manual accessible in the immediate vicinity of the device.
1.2Target 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.
1.3Symbolism 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.
lList
The dot set in front indicates a list with no implied sequence.
àAction
This arrow indicates a single action.
1Sequence
Numbers set in front indicate successive steps in a procedure.
4LEVEL SWITCH 8112 •with transistor output
1About this document
32051-EN-120418

2For your safety
2.1Authorised personnel
All operations described in this operating instructions manual must be
carried out only by trained specialist personnel authorised by the plant
operator.
During work on and with the device the required personal protective
equipment must always be worn.
2.2Appropriate use
The LEVEL SWITCH 8112 is a sensor for level detection.
You can find detailed information on the application range in chapter
"Product description".
Operational reliability is ensured only if the instrument is properly used
according to the specifications in the operating instructions manual as
well as possible supplementary instructions.
For safety and warranty reasons,any invasive work on the device
beyond that described in the operating instructions manual may be
carried out only by personnel authorised by the manufacturer.Arbitrary
conversions or modifications are explicitly forbidden.
2.3Warning 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.
2.4General safety instructions
This 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 as well as all prevailing safety
regulations and accident prevention rules.
The instrument must only be operated in a technically flawless and
reliable condition.The operator is responsible for trouble-free
operation of the instrument.
During the entire duration of use,the user is obliged to determine the
compliance of the necessary occupational safety measures with the
current valid rules and regulations and also take note of new
regulations.
LEVEL SWITCH 8112 •with transistor output 5
2For your safety
32051-EN-120418

2.5Safety label on the instrument
The safety approval markings and safety tips on the device must be
observed.
2.6CE conformity
This device fulfills the legal requirements of the applicable EC
guidelines.By attaching the CE mark,we provide confirmation of
successful testing.
2.7SIL conformity
LEVEL SWITCH 8112 fulfills the requirements to functional safety
according to IEC 61508 resp.IEC 61511.You find further information
in the Safety Manual "LEVEL SWITCH".
2.8Safety instructions for Ex areas
Please note the Ex-specific safety information for installation and
operation in Ex areas.These safety instructions are part of the
operating instructions manual and come with the Ex-approved
instruments.
6LEVEL SWITCH 8112 •with transistor output
2For your safety
32051-EN-120418

3Product description
3.1Structure
The scope of delivery encompasses:
lLEVEL SWITCH 8112 point level switch
lDocumentation
-this operating instructions manual
-Safety Manual "Functional safety according to IEC 61508
resp.IEC 61511 (SIL)"
-Ex-specific"Safety instructions"(with Ex versions)
-if necessary,further certificates
The LEVEL SWITCH 8112 consists of the components:
lHousing cover
lHousing with electronics
lProcess fitting with tuning fork
1
2
3
Fig.1:LEVEL SWITCH 8112 -with plastic housing
1Housing cover
2Housing with electronics
3Process fitting
The type label contains the most important data for identification and
use of the instrument:
lArticle number
lSerial number
lTechnical data
Scope of delivery
Constituent parts
Type label
LEVEL SWITCH 8112 •with transistor output 7
3Product description
32051-EN-120418

lArticle numbers,documentation
In addition to the type label outside on the instrument,you find the
serial number also inside the instrument.
3.2Principle of operation
LEVEL SWITCH 8112 is a point 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.The small
tuning fork allows use in all kinds of tanks and vessels.Thanks to its
simple and rugged measuring system,LEVEL SWITCH 8112 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 LEVEL SWITCH 8112 continuously
monitors via frequency evaluation the following criteria:
lStrong corrosion or damage on the tuning fork
lLoss of vibration
lLine 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 output is open (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 electronics
module and converted into a switching command.
LEVEL SWITCH 8112 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 operated directly (e.g.a
warning system,a pump etc.).
The data for power supply are specified in chapter "Technical data".
Application area
Functional principle
Voltage supply
8LEVEL SWITCH 8112 •with transistor output
3Product description
32051-EN-120418

3.3Operation
The switching condition of LEVEL SWITCH 8112 can be checked
when the housing is closed (signal lamp). With the basic setting,
products with a density >0.7g/cm³(0.025 lbs/in³)can be detected.
The instrument can be adapted if products with lower density should
be measured.
On the electronics module you will find the following indicating and
adjustment elements:
lSignal lamp for indication of the switching condition (green/red)
lDIL switch for sensitivity adjustment
lMode adjustment for selection of the switching condition (A/B)
3.4Storage and transport
Your instrument was protected by packaging during transport.Its
capacity to handle normal loads during transport is assured by a test
according to DIN EN 24180.
The packaging of standard instruments consists of environment-
friendly,recyclable cardboard.The sensor is also equipped with a
protective cap of ABS.For special versions,PE foam or PE foil is also
used.Dispose of the packaging material via specialised recycling
companies.
Transport must be carried out under consideration of the notes on the
transport packaging.Nonobservance of these instructions can cause
damage to the device.
The delivery must be checked for completeness and possible transit
damage immediately at receipt.Ascertained transit damage or
concealed defects must be appropriately dealt with.
Up to the time of installation,the packages must be left closed and
stored according to the orientation and storage markings on the
outside.
Unless otherwise indicated,the packages must be stored only under
the following conditions:
lNot in the open
lDry and dust free
lNot exposed to corrosive media
lProtected against solar radiation
lAvoiding mechanical shock and vibration
lStorage and transport temperature see chapter "Supplement -
Technical data -Ambient conditions"
lRelative humidity 20 …85 %
Packaging
Transport
Transport inspection
Storage
Storage and transport
temperature
LEVEL SWITCH 8112 •with transistor output 9
3Product description
32051-EN-120418

4Mounting
4.1General instructions
Make sure that all parts of the instrument exposed to the process,in
particular the sensor element,process seal and process fitting,are
suitable for the existing process conditions.These include above all
the process pressure,process temperature as well as the chemical
properties of the medium.
You can find the specifications in chapter "Technical data"and on the
type label.
In general,LEVEL SWITCH 8112 can be installed in any position.The
instrument only has to be mounted in such a way that the tuning fork is
at the height of the desired switching point.
The tuning fork has lateral markings (notches)that indicate the
switching point with vertical mounting.The switching point refers to
water with the basic setting of the sensitivity switch ≥0.7g/cm³
(0.025 lbs/in³). When mounting LEVEL SWITCH 8112,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 -water 1g/cm³(0.036 lbs/in³). For
products <0.7g/cm³(0.025 lbs/in³)and >0.5g/cm³(0.018 lbs/in³)the
density switch must be set to ≥0.5g/cm³.
Suitability for the proc-
ess conditions
Switching point
10 LEVEL SWITCH 8112 •with transistor output
4Mounting
32051-EN-120418

2
3
14
Fig.2:Installation vertical
1Switching point approx.13 mm (0.51 in)
2Switching point with lower density
3Switching point with higher density
4Switching point approx.27 mm (1.06 in)
1
Fig.3:Horizontal installation
1Switching point
LEVEL SWITCH 8112 •with transistor output 11
4Mounting
32051-EN-120418

1
2
Fig.4:Horizontal installation (recommended mounting position,particularly for
adhesive products)
1Switching point
2Marking with screwed version on top,with flange versions directed to the
flange holes
With flange versions,the fork is directed as follows to the flange holes.
Fig.5:Fork position with flange versions
Use the recommended cables (see chapter "Connecting to power
supply")and tighten the cable gland.
You can give your instrument additional protection against moisture
penetration by leading the connection cable downward in front of the
cable entry.Rain and condensation water can thus drain off.This
applies mainly to outdoor mounting as well as installation in areas
where high humidity is expected (e.g.through cleaning processes)or
on cooled or heated vessels.
Moisture
12 LEVEL SWITCH 8112 •with transistor output
4Mounting
32051-EN-120418

Fig.6:Measures against moisture penetration
Caution:
Do not hold LEVEL SWITCH 8112 on the tuning fork.Particularly with
flange or tube versions,the tuning fork can be damaged just by the
weight of the instrument.Transport coated instruments very carefully
and avoid touching the tuning fork.
Remove the packaging or the protective cover just before installation.
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 specified in chapter "Technical data"
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 the instrument in!Applying
tightening force can damage internal parts of the housing.
Use the hexagon above the thread for screwing in.
4.2Instructions for installation
LEVEL SWITCH 8112 has a defined thread starting point.This means
that every LEVEL SWITCH 8112 is in the same fork position after
being screwed in.Remove therefore the supplied seal from the thread
of LEVEL SWITCH 8112.This seal is not required when using a
welded socket with O-ring in front.
Transport
Pressure/Vacuum
Handling
Welded socket
LEVEL SWITCH 8112 •with transistor output 13
4Mounting
32051-EN-120418

Keep in mind that this welded socket is not suitable for coated
instrument versions.
Screw LEVEL SWITCH 8112 completely into the welded socket.The
later position can be determined already before welding.Mark the
appropriate position of the welded socket.Before welding,unscrew
LEVEL SWITCH 8112 and remove the rubber ring from the welded
socket.The welded socket has a marking (notch). Weld the socket
with the notch facing upward,or in case of pipelines (DN 32 up to
DN 50), aligned with the direction of flow.
1
Fig.7:Marking on the welded socket
1Marking
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.On the screwed version you will find a marking on
the hexagon.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 reach the
recommended installation position.
With flange versions,the fork is directed to the flange holes.
When used in adhesive and viscous products,the tuning fork should
protrude into the vessel to avoid buildup.For that reason,sockets for
flanges and mounting bosses should be avoided when mounting
horizontally.
IfLEVEL SWITCH 8112 is mounted in the filling stream,unwanted
false measurement signals can be generated.For this reason,mount
LEVEL SWITCH 8112 at a position in the vessel where no
disturbances,e.g.from filling openings,agitators,etc., can occur.
This applies particularly to instrument types with long extension tube.
Adhesive products
Inflowing medium
14 LEVEL SWITCH 8112 •with transistor output
4Mounting
32051-EN-120418

Fig.8:Inflowing medium
To minimise flow resistance caused by the tuning fork,LEVEL
SWITCH 8112 should be mounted in such a way that the surfaces of
the blades are parallel to the product movement.
Due to the effects of agitators,equipment vibration or similar,the level
switch can be subjected to strong lateral forces.For this reason,do not
use an overly long extension tube for LEVEL SWITCH 8112,but check
if you can mount a level switch on the side of the vessel in horizontal
position.
Extreme vibration caused by the process or the equipment,e.g.
agitators or turbulence in the vessel,can cause the extension tube of
LEVEL SWITCH 8112 to vibrate in resonance.This leads to increased
stress on the upper weld joint.Should a longer tube version be
necessary,you can provide a suitable support directly above the
tuning fork to secure the extension tube.
This measure applies mainly to applications in Ex areas category 1Gor
WHG.Make sure that the tube is not subject to bending stress due to
this measure.
Flows
Agitators
LEVEL SWITCH 8112 •with transistor output 15
4Mounting
32051-EN-120418

Fig.9:Lateral straining of LEVEL SWITCH 8112
16 LEVEL SWITCH 8112 •with transistor output
4Mounting
32051-EN-120418

5Connecting to power supply
5.1Preparing the connection
Always keep in mind the following safety instructions:
lConnect only in the complete absence of line voltage
In hazardous areas you must take note of the respective regulations,
conformity and type approval certificates of the sensors and power
supply units.
Connect the operating voltage according to the following diagrams.
Take note of the general installation regulations.As a rule,connect
LEVEL SWITCH 8112 to vessel ground (PA), or in case of plastic
vessels,to the next ground potential.On the side of the instrument
housing there is a ground terminal between the cable entries.This
connection serves to drain offelectrostatic charges.InEx applications,
the installation regulations for hazardous areas must be given priority.
The data for power supply are specified in chapter "Technical data".
The instrument is connected with standard two-wire cable without
screen.If electromagnetic interference is expected which is above the
test values of EN 61326 for industrial areas,screened cable should be
used.
Use cable with round cross-section.Acable outer diameter of 5…9mm
(0.2…0.35 in)ensures the seal effect of the cable gland.If you are
using cable with a different diameter or cross-section,exchange the
seal or use a suitable cable gland.
In hazardous areas,only use approved cable connections for LEVEL
SWITCH 8112.
Take note of the corresponding installation regulations for Ex
applications.
Cover all housing openings conforming to standard according to
EN 60079-1.
5.2Connection procedure
With Ex instruments,the housing cover may only be opened if there is
no explosive atmosphere present.
Proceed as follows:
1Unscrew the housing cover
2Loosen compression nut of the cable entry
3Remove approx.10 cm (4in)of the cable mantle,strip approx.
1cm (0.4in)of insulation from the ends of the individual wires
4Insert the cable into the sensor through the cable entry
Note safety instructions
Take note of the
safety instruc-
tions for Ex ap-
plications
Voltage supply
Connection cable
Connection ca-
ble for Ex appli-
cations
LEVEL SWITCH 8112 •with transistor output 17
5Connecting to power supply
32051-EN-120418

5Open the terminals with a screwdriver
6Insert the wire ends into the open terminals according to the wiring
plan
7Tighten the terminals with a screwdriver
8Check the hold of the wires in the terminals by lightly pulling on
them
9Tighten the compression nut of the cable entry.The seal ring must
completely encircle the cable
10 Screw the housing cover back on
The electrical connection is finished.
5.3Wiring plan,single chamber housing
T
10-55V DC
1 PNP2 3 4 1 NPN2 3 4
A
B
0,5g/cm3
0,7g/cm3
max 400mA
out
1 2 3 4
+
++
3
5
1
2
4
Fig.10:Electronics and connection compartment,single chamber housing
1Control lamp
2DIL switch for mode adjustment
3DIL switch for switching point adaptation
4Ground terminal
5Connection terminals
We recommend connecting LEVEL SWITCH 8112 in such a way that
the switching circuit is open when there is a level signal,line break or
failure (safe condition).
The instrument is used to control relays,contactors,magnet valves,
warning lights,horns as well as PLC inputs.
Caution:
There is no reverse polarity protection.Take note of the polarity of the
output lines.
Electronics and connec-
tion compartment
Wiring plan
18 LEVEL SWITCH 8112 •with transistor output
5Connecting to power supply
32051-EN-120418

+ -
1 2 3 4
+-
Fig.11:NPN action
+ -
1 2 3 4
+-
Fig.12:PNP action
LEVEL SWITCH 8112 •with transistor output 19
5Connecting to power supply
32051-EN-120418

6Set up
6.1General information
The figures in brackets refer to the following illustrations.
The switching condition of the electronics can be checked with closed
housing cover (control lamp). In the basic setting,products with a
density >0.7g/cm³(0.025 lbs/in³)can be detected.For products with
lower density,the switch must be set to >0.5g/cm³(0.018 lbs/in³).
On the electronics module you will find the following indicating and
adjustment elements:
lSignal lamp (1)
lDIL switch for mode adjustment -A/B(2)
lDIL switch for sensitivity adjustment (3)
Note:
For test purposes,immerse the tuning fork of LEVEL SWITCH 8112
always in liquids.Do not test the function of LEVEL SWITCH 8112 with
your hand.This can damage the sensor.
6.2Adjustment elements
1234
1
2
3
Fig.13:Oscillator SWE60T-Transistor output
1Signal lamp (LED)
2DIL switch for mode adjustment
3DIL switch for sensitivity adjustment
Control lamp for indication of the switching status
lGreen =Output closed
lRed =Output open
lred (flashing)=failure
Function/Configuration
Signal lamp (1)
20 LEVEL SWITCH 8112 •with transistor output
6Set up
32051-EN-120418