Endress+Hauser Nivotester FailSafe FTL825 User manual

BA01038F/00/EN/01.11
71148747
Operating Instructions
Nivotester FailSafe FTL825
Vibronic
With intrinsically safe signal circuit for point level switch
Liquiphant FailSafe FTL8x

Nivotester FailSafe FTL825 Table of contents
2Endress+Hauser
Table of contents
1 Important document information . . . . . 3
1.1 About this document . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Notes on safety conventions and icons . . . . . . . . . . 4
2 Basic safety instructions . . . . . . . . . . . . 5
2.1 Personnel requirements . . . . . . . . . . . . . . . . . . . . . 5
2.2 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Occupational safety . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 Operational safety . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.5 Product safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Product description . . . . . . . . . . . . . . . 6
3.1 Signal transmission . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Signal analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3 Product structure . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 System components . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Incoming acceptance and product
identification. . . . . . . . . . . . . . . . . . . . . 8
4.1 Incoming acceptance . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 Product configuration: www.endress.com . . . . . . . . 9
4.3 Product identification . . . . . . . . . . . . . . . . . . . . . . . 9
5 Storage and transport . . . . . . . . . . . . . 10
5.1 Storage conditions . . . . . . . . . . . . . . . . . . . . . . . . 10
5.2 Transporting the product . . . . . . . . . . . . . . . . . . . 10
6 Installation . . . . . . . . . . . . . . . . . . . . . 11
6.1 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.2 Installation instructions . . . . . . . . . . . . . . . . . . . . . 11
6.3 Mounting the device . . . . . . . . . . . . . . . . . . . . . . 14
6.4 Post-installation check . . . . . . . . . . . . . . . . . . . . . 15
7 Electrical connection . . . . . . . . . . . . . 15
7.1 Cable diameter and wire cross-section . . . . . . . . . 15
7.2 Connection data . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7.3 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7.4 Connecting the device . . . . . . . . . . . . . . . . . . . . . 17
7.5 Function monitoring . . . . . . . . . . . . . . . . . . . . . . . 18
7.6 Post-connection check . . . . . . . . . . . . . . . . . . . . . 18
8 Operation . . . . . . . . . . . . . . . . . . . . . 19
8.1 Operating and display elements . . . . . . . . . . . . . . 19
9 Commissioning. . . . . . . . . . . . . . . . . . 20
9.1 Function check . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
9.2 Interlocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
9.3 Performing a proof test . . . . . . . . . . . . . . . . . . . . . 21
9.4 Device behavior during operation . . . . . . . . . . . . . 22
10 Troubleshooting. . . . . . . . . . . . . . . . . . 24
10.1 Response of outputs to alarms . . . . . . . . . . . . . . . . 24
10.2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 24
10.3 Replacing the fuses . . . . . . . . . . . . . . . . . . . . . . . . 28
10.4 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
11 Technical data . . . . . . . . . . . . . . . . . . . 30
12 Repair . . . . . . . . . . . . . . . . . . . . . . . . . 30
12.1 Repairing Ex-certified devices . . . . . . . . . . . . . . . . 30
12.2 Replacing a device . . . . . . . . . . . . . . . . . . . . . . . . 30
13 Maintenance . . . . . . . . . . . . . . . . . . . . 30
14 Return . . . . . . . . . . . . . . . . . . . . . . . . . 31
15 Disposal . . . . . . . . . . . . . . . . . . . . . . . . 31

Nivotester FailSafe FTL825 Important document information
Endress+Hauser 3
1 Important document information
1.1 About this document
1.1.1 Document function
These Operating Instructions contain all the information that is required in the various phases of the
life cycle of the device: from product identification, incoming acceptance and storage, to mounting,
connection, operation and commissioning through to troubleshooting, maintenance and disposal.
1.1.2 Additional standard device documentation
1.1.3 Safety Instructions (XA) for the device
Depending on the device approval Safety Instructions (XA) are supplied with the device. These are
considered an integral part of the Operating Instructions.
!Note!
The document types listed are available at: www.endress.com Download
Document Purpose and content of the document
TI01027F Planning aid for your device (Technical Information)
The document contains all the technical data on the device and provides an overview
of the accessories and other products that can be ordered for the device.
TI00367F Protective housing IP 66 for field mounting of top-hat rail devices
SD00350F Functional Safety Manual
Document Type of protection
XA00603F ATEX Ex ia G/D
ATEX II (1)G [Ex ia Ga] IIC
ATEX II (1)D [Ex ia Da] IIIC,
IECEx Ex ia G/D
IECEx [Ex ia Ga] IIC
IECEx [Ex ia Da] IIIC,
ATEX/IECEx Ex ia G/D
ATEX II (1)G [Ex ia Ga] IIC
ATEX II (1)D [Ex ia Da] IIIC
IECEx [Ex ia Ga] IIC
IECEx [Ex ia Da] IIIC
XA00647F CSA C/US AIS/ANI
AIS Cl. I, II, III, Div 1, Gr. A-G, [AEx/Ex ia] IIC
ANI Cl. I, Div 2 Gr. A-D [AEx/Ex ic/nL] IIC
XA00646F FM C/US AIS/ANI
AIS Cl. I, II, III, Div 1, Gr. A-G, [AEx/Ex ia] IIC
ANI Cl. I, Div 2 Gr. A-D [AEx/Ex ic/nL] IIC
XA00663F NEPSI Ex ia G/D
NEPSI [Ex ia Ga] IIC
NEPSI [Ex ia Da] IIIC

Important document information Nivotester FailSafe FTL825
4Endress+Hauser
1.2 Notes on safety conventions and icons
In order to highlight safety-related or alternative operating procedures in the manual, the following
conventions have been used, each indicated by a corresponding icon in the margin.
Safety instructions
#Warning!
Indicates an action or procedure which, if not performed correctly, can result in serious personal
injury, a safety hazard or the destruction of the device.
"Caution!
Indicates an action or procedure which, if not performed correctly, can result in personal injury or
the incorrect operation of the device.
!Note!
Indicates an action or procedure which, if not performed correctly, can have an indirect effect on
operation or trigger an unexpected response on the part of the device.
Type of protection
0Explosion-protected, type-examined equipment
If this symbol appears on the nameplate of the device, the device can be used in hazardous or non-
hazardous areas according to its approval.
-Hazardous area
This symbol is used in the drawings of these Operating Instructions to indicate hazardous areas.
Devices in hazardous areas, or cables for such devices, must have an appropriate type of protection.
.Safe area (non-hazardous area)
This symbol is used in the drawings of these Operating Instructions to indicate non-hazardous areas.
Devices in the non-hazardous area also have to be certified if connecting cables lead into the
hazardous area.
Electrical symbols
%Direct current
A terminal at which DC voltage is present or through which direct current flows.
&Alternating current
A terminal at which alternating voltage (sinusoidal) is present or through which alternating current
flows.
Connecting cable immunity to temperature change
Indicates that the connecting cables must be able to withstand temperatures of at least 85 °C.
LED symbols
Not relevant
Off
Flashing
Lit
t >85°C

Nivotester FailSafe FTL825 Basic safety instructions
Endress+Hauser 5
2 Basic safety instructions
2.1 Personnel requirements
The personnel for installation, commissioning, diagnostics and maintenance must fulfill the
following requirements:
• Trained, qualified specialists must have a relevant qualification for this specific task
• Are authorized by the plant owner/operator
• Are familiar with federal/national regulations
• Before beginning work, the specialist staff must have read and understood the instructions in the
Operating Instructions and supplementary documentation as well as in the certificates (depending
on the application)
• Follow instructions and comply with conditions
• Be instructed and authorized according to the requirements of the task by the facility's owner-
operator
• Follow the instructions in these Operating Instructions
2.2 Designated use
Functional Safety Manual
"Caution!
Pay close attention to the information in the separate SIL documentation SD00350F for functional
safety requirements in accordance with IEC 61508.
Application and media
The measuring device described in this manual may only be used in conjunction with Liquiphant
FailSafe FTL8x from Endress+Hauser. In compliance with the limit values specified in the
"Technical data" section and the general conditions indicated in the manual and supplementary
documentation, the measuring system may only be used for the following measurements:
• Measured variables: point level
To ensure that the measuring device remains in proper operating condition for its service life, all the
limit values must be observed.
• Technical data in the related documentation ä3.
Incorrect use
The manufacturer is not liable for damage resulting from improper or non-designated use.
2.3 Occupational safety
When working on or with the device, always wear the necessary personal protective equipment as
defined in national regulations.
2.4 Operational safety
"Caution! Risk of injury.
• Only operate the device if it is in a perfect technical condition free from errors and faults.
• The operator is responsible for the trouble-free operation of the device.
Conversions to the device
Unauthorized modifications to the device are not permitted.

Product description Nivotester FailSafe FTL825
6Endress+Hauser
Repair
To ensure operational safety:
• Only perform repair work on the device if this is expressly permitted.
• Comply strictly with national regulations concerning the repair of electrical equipment.
• Only use genuine Endress+Hauser spare parts and accessories.
Hazardous area
To exclude any risks to individuals or the facility when operating the device in the hazardous areas
(e.g. explosion protection, pressure equipment safety):
• Based on the nameplate, check whether the ordered device is permitted for the intended use in
the hazardous area.
• Comply with the instructions in the separate supplementary documentation, which is an integral
part of this manual.
2.5 Product safety
This measuring device is designed to meet state-of-the-art safety requirements in accordance with
sound engineering practice, has been tested and left the factory in a condition in which it is safe to
operate.
It meets general safety standards and legal requirements. Furthermore, it complies with the EC
directives which are listed in the device-specific EC Declaration of Conformity. Endress+Hauser
confirms this by affixing the CE mark to the device.
3 Product description
The Nivotester FailSafe FTL825 is a transmitter power supply unit for the Liquiphant FailSafe
FTL8x. Outstanding features of the Nivotester FailSafe FTL825 include:
• Fail-safe point level detection in liquids
• For point level switches up to Zone 0
• Pump dry running protection and overfill protection for tanks with flammable, explosive, toxic
(water-polluting) liquids
• Use in safety systems requiring functional safety to SIL3 in accordance with IEC 61508 Ed.2.0 /
IEC 61511-1 / ISA 84-1
3.1 Signal transmission
The Nivotester supplies direct current to the Liquiphant FailSafe FTL8x point level switch via a two-
wire cable. At the same time, it analyzes the current values (4 to 20 mA discrete) of the Liquiphant
and returns a switching signal. The signal inputs of the Nivotester FTL825 are galvanically isolated
from the mains and the output and can be ordered as intrinsically safe inputs.
LIVE signal
It is possible to automatically check whether a Liquiphant FailSafe FTL8x is connected. For this
purpose a LIVE signal is modulated within the range limits.
The LIVE signal is a square-wave signal of 0.25 Hz and ±0.5 mA amplitude (the signal changes by
1 mA every 2000 ms ±50 ms).

Nivotester FailSafe FTL825 Product description
Endress+Hauser 7
3.2 Signal analysis
The Nivotester FailSafe FTL825:
• Evaluates the current and switches the safety contacts for the level alarm accordingly
• Switches a signaling contact in addition to the safety contacts
• Switches a separate fault-signaling contact in the event of a device malfunction
• Evaluates a dynamic signal (LIVE signal) and indicates the status of this signal using an LED
• Signals the switching state on the front panel by means of a yellow LED
3.3 Product structure
3.3.1 Top terminal blocks
• 2 screw terminals: sensor connection MAX detection (91, 92)
• 2 screw terminals: sensor connection MIN detection (83, 82)
3.3.2 Bottom terminal blocks
• 4 screw terminals: fault-signaling contact (4, 5, 6) and remote control (52)
• 4 screw terminals: supply voltage (1, 2) and unlocking (50, 51)
• 3 screw terminals: safety contacts (13, 23) and signaling contact (31)
• 3 screw terminals: safety contacts (14, 24) and signaling contact (32)
3.3.3 Proof test button
The proof test button is used to confirm configuration changes and enable the proof test.
3.3.4 Interlock switch
The interlock switch is used to secure a certain operating mode.
3.3.5 Light emitting diodes (LEDs)
The light emitting diodes are used to indicate different operating states.
3.3.6 Fuses
The two output channels are protected against damage by two fuses.

Incoming acceptance and product identification Nivotester FailSafe FTL825
8Endress+Hauser
3.4 System components
The measuring system consists of the following components:
• Nivotester FailSafe FTL825 (transmitter supply unit)
• Liquiphant FailSafe FTL8x with FEL85 electronic insert (point level switch)
TI01005F_xx_000
1 Liquiphant FailSafe FTL8x with FEL85 electronic insert (4-20 mA)
2 Separate switching unit: Nivotester FailSafe FTL825
3Actuator
4 Incoming acceptance and product identification
4.1 Incoming acceptance
Is the order code on the delivery note (1) identical to the order code on the product sticker (2)?
Do the data on the nameplate match the order data and the delivery note?
.
1
2
3
-
13 23 31
91 92
45652
A0013696
TI01005F_xx_015
TI01005F_xx_016
DELIVERY NOTE
1= 2

Nivotester FailSafe FTL825 Incoming acceptance and product identification
Endress+Hauser 9
4.2 Product configuration: www.endress.com
Detailed ordering information is available:
• In the Product configurator on the Endress+Hauser website: www.endress.com Select
countryInstrumentsSelect deviceProduct page function: Configure this product
• From your Endress+Hauser sales center: www.endress.com/worldwide
!Note! Product configurator - the tool for individual product configuration
• Up-to-date configuration data
• Direct entry of data specific to the measuring point, such as the measuring range or operating
language, depending on the device
• Exclusion criteria automatically checked
• Automatic order code generation with code breakdown output in PDF or Excel format
• Possible to order directly in the Endress+Hauser online shop
4.3 Product identification
It is possible to identify the measuring device in the following ways:
• Using the nameplate specifications
• Using the order code with a breakdown of the device features on the delivery note
• By entering the serial number on the nameplates into the W@M Device Viewer
(www.endress.com/deviceviewer): All the information pertaining to the measuring device is
displayed.
For an overview of the scope of the technical documentation supplied with the device, enter the
serial number on the nameplates into the W@M Device Viewer (www.endress.com/deviceviewer)
A0013696
TI01005F_xx_018
DELIVERY NOTE
Made in Germany, 79689 Maulburg
FTL825
MIN
MAX

Storage and transport Nivotester FailSafe FTL825
10 Endress+Hauser
4.3.1 Nameplate
BA01038F_04
1 Order code
2 Certificate symbols
3 Document numbers of Safety Instructions: e.g. XA, ZD, ZE
4 Certificate- and approval-specific data
5CEmark
6Layoutnumber
7 Power supply data
8 Barcode (serial number)
9 Information on certificates and approvals
10 Serial number
11 Order number
12 TAG number
13 Manufacturer's address
14 Barcode (order number)
15 Connection data
5 Storage and transport
5.1 Storage conditions
–20 to +85 °C preferably at +20 °C (–4 to +185 °F preferably +68 °F)
5.2 Transporting the product
Transport the measuring device to the measuring point in its original packaging.
Nivotester
-20 °C Tamb +60 °C
-20 °C Tamb +50 °C (Anreihmontage/
row mounting)
50 51
L-
12
L+
652
45
32
14
24
13 23 31
250 V AC, 2 A, 500 VA
40 V DC, 2 A, 80 W (cos 0,7)
Contact rating
Ser. no.:
Kom. no.:
FTL825-
U:
I:
U:
I:
TAG no.:
3
8
7
6
1
15
10
245
9
11121314