IFM efector 160 LR3000 User manual

Operating instructions
Electronic level sensor
LR3000
704739 / 00 03 / 2010
UK

2
Contents
1 Preliminary note���������������������������������������������������������������������������������������������������4
1�1 Symbols used ������������������������������������������������������������������������������������������������4
2 Safety instructions �����������������������������������������������������������������������������������������������4
3 Items supplied������������������������������������������������������������������������������������������������������5
4 Functions and features ����������������������������������������������������������������������������������������6
4�1 Operation with single probe���������������������������������������������������������������������������6
4�2 Operation with coaxial probe �������������������������������������������������������������������������6
4�3 Applications ���������������������������������������������������������������������������������������������������7
5 Function���������������������������������������������������������������������������������������������������������������8
5�1 Measuring principle ���������������������������������������������������������������������������������������8
5�2 Features of the unit����������������������������������������������������������������������������������������8
6 Installation����������������������������������������������������������������������������������������������������������12
6�1 Installation location / environment ���������������������������������������������������������������12
6�1�1 Unit with single probe �������������������������������������������������������������������������12
6�1�2 Unit with coaxial probe �����������������������������������������������������������������������15
6�2 Installation of the probe �������������������������������������������������������������������������������15
6�2�1 Installation of the rod ��������������������������������������������������������������������������15
6�2�2 Installation of the coaxial pipe ������������������������������������������������������������16
6�3 Shortening of the probe �������������������������������������������������������������������������������16
6�3�1 Shortening of the rod ��������������������������������������������������������������������������16
6�3�2 Shortening of the coaxial pipe ������������������������������������������������������������17
6�4 Installation of the unit with single probe�������������������������������������������������������17
6�4�1 Installation in metal tanks �������������������������������������������������������������������17
6�4�2 Installation in plastic tanks������������������������������������������������������������������19
6�4�3 Installation using a flange plate ����������������������������������������������������������19
6�5 Installation of the unit with coaxial probe in the tank �����������������������������������20
7 Electrical connection������������������������������������������������������������������������������������������21
8 Operating and display elements ������������������������������������������������������������������������22
9 Menu������������������������������������������������������������������������������������������������������������������23
9�1 Menu structure���������������������������������������������������������������������������������������������23
9�2 Explanation of the menu������������������������������������������������������������������������������24

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10 Parameter setting ��������������������������������������������������������������������������������������������25
10�1 General parameter setting�������������������������������������������������������������������������25
10�2 Basic settings (unit on delivery)�����������������������������������������������������������������27
10�2�1 Entering the probe length �����������������������������������������������������������������27
10�2�2 Setting to the medium�����������������������������������������������������������������������27
10�2�3 Entering the type of probe used �������������������������������������������������������27
10�3 Configuration of the display �����������������������������������������������������������������������28
10�4 Offset setting����������������������������������������������������������������������������������������������28
10�5 Setting of output signals ����������������������������������������������������������������������������28
10�5�1 Setting of the output function for OUT1 ��������������������������������������������28
10�5�2 Setting of switching limits (hysteresis function) ��������������������������������28
10�5�3 Setting of switching limits (window function) ������������������������������������28
10�5�4 Setting of the switch-off delay�����������������������������������������������������������29
10�5�5 Setting of the output function for OUT2 (analogue output) ��������������29
10�5�6 Scaling of the analogue value ����������������������������������������������������������29
10�5�7 Response of the outputs in case of a fault ���������������������������������������29
10�5�8 Setting of the delay time after signal loss �����������������������������������������29
10�6 Reset of all parameters to factory setting ��������������������������������������������������30
10�7 Changing basic settings ����������������������������������������������������������������������������30
10�7�1 New entering of the probe length �����������������������������������������������������30
10�7�2 Setting to another medium ���������������������������������������������������������������30
10�7�3 New entering of the type of probe used��������������������������������������������31
11 Operation ���������������������������������������������������������������������������������������������������������31
11�1 Operating indicators ����������������������������������������������������������������������������������31
11�2 Reading of the set parameters�������������������������������������������������������������������31
11�3 Changing the display unit in the Run mode �����������������������������������������������32
11�4 Error indications�����������������������������������������������������������������������������������������32
11�5 Output response in different operating states ��������������������������������������������33
12 Scale drawing ��������������������������������������������������������������������������������������������������34
13 Technical data��������������������������������������������������������������������������������������������������35
13�1 Setting ranges ������������������������������������������������������������������������������������������36
14 Maintenance ����������������������������������������������������������������������������������������������������37
15 Factory setting �������������������������������������������������������������������������������������������������38

4
Preliminary note1
Symbols used1.1
►Instruction
> Reaction, result
[…] Designation of pushbuttons, buttons or indications
→Cross-reference
Important note
Non-compliance can result in malfunctions or interference�
Information
Supplementary note�
Safety instructions2
Please read this document prior to set-up of the unit� Ensure that the product is•
suitable for your application without any restrictions�
The unit must be connected by a qualified electrician�•
The national and international regulations for the installation of electrical equip-•
ment must be adhered to�
The unit complies with the standard EN 61000-6-4 and is a class A product�•
The radiated energy of the microwaves is, for example, much below that of
mobile phones� According to the current state of science the operation of the
unit can be classified to be harmless to human health�
The unit may cause radio interference in domestic areas� If interference occurs,•
the user must take appropriate remedial actions�
Improper or non-intended use may lead to malfunctions of the unit or to un-•
wanted effects in your application� That is why installation, electrical connec-
tion, set-up, operation and maintenance of the unit must only be carried out by
qualified personnel authorised by the machine operator�

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UK
Items supplied3
Level sensor LR3000•
Operating instructions•
In addition, the following is necessary for installation and operation:
1rod(foroperationoftheunitwithsingleprobe→4.1)•
plus1coaxialpipe(foroperationoftheunitwithcoaxialprobe→4.2)•
mounting material•
The following components are available as accessories:
Rods Length (cm / inch) Order number
24 / 9�5 E43203
45 / 17�7 E43204
70 / 27�6 E43205
100 / 39�4 E43207
120 / 47�2 E43208
140 / 55�1 E43209
160 / 63�0 E43210
Coaxial pipes
with process connection G¾
Length (cm / inch) Order number
24 / 9�5 E43211
45 / 17�7 E43212
70 / 27�6 E43213
100 / 39�4 E43214
120 / 47�2 E43215
140 / 55�1 E43216
160 / 63�0 E43217
Coaxial pipes with process
connection ¾“ NPT
Length (cm / inch) Order number
45 / 17�7 E43218
70 / 27�6 E43219
100 / 39�4 E43220
160 / 63�0 E43221
Flange plates Size / process connection Order number
73 - 90 / G¾ E43201
65 - 80 / G¾ E43202
73 - 90 / ¾” NPT E43206

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Only use rods and coaxial pipes from ifm electronic� The optimum function
is not ensured when using components from other manufacturers�
For the correct function when used with single probe, the unit needs a
large enough metal launching plate� The flange plates that are available as
accessories are not sufficient as launching plates (for suitable launching
plates→6.4.1/6.4.2).
Functions and features4
The unit continuously detects the level in tanks and generates output signals ac-
cording to the parameter settings�
2 outputs are available: one analogue output and one switching output� They can
be set separately��
Operation with single probe4.1
The single probe is made up of one individual rod� Operation with single probe is
suited for the detection of aqueous media, in particular of heavily soiled aqueous
media�
For the correct function with single probe, the unit needs a large enough
metal launching plate� It is necessary for transferring the microwave pulse
to the tank with optimum transmission power�
For installation in closed metal tanks, the tank lid serves as a launching
plate� For installation in open metal tanks, tanks made of plastic or metal
tanks with plastic lids a sufficiently large fixing plate, a metal plate or simi-
larmustbeused(→6.4.1/6.4.2).
For operation with single probe, minimum distances to tank walls, objects
in the tank, bottom of the tank and further level sensors must be adhered
to(→6.1.1).
Operation with coaxial probe4.2
The coaxial probe is made up of an inner rod and an outer probe pipe (coaxial
pipe)� The rod is centered in the coaxial pipe by one or several spacers�
In case of operation with a coaxial probe media with a low dielectric constant (e�g�
oil and oil-based media) are detected in addition to aqueous media�
No launching plate is required for operation with coaxial probe� Further-
more, no minimum distances to tank walls and objects in the tank are
required�

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Applications4.3
Water, water-based media•
Oils, oil-based media (only for operation with coaxial probe)•
Medium temperature: 0…80 °C (permanent); 0…90 °C (short-term)•
Tank pressures: -1���4 bar•
Application examples:
Detection of coolant emulsion in a machine tool�•
Detection of cleaning liquid in a parts cleaning system�•
Monitoring of hydraulic oil in a hydraulic power unit (only for operation with•
coaxial probe)
Restriction of the application area
The unit is not suitable for bulk materials (e�g� plastic granulates)•
If the unit is to be used in acids or alkalis, in hygienic areas or in electroplating•
applications:firstcheckthecompatibilityoftheproductmaterials(→chapter
13, Technical data) with the media to be monitored�
Incorrect measurements or signal loss may be caused by the following media:•
Highly absorbing surfaces (e�g� foam)�-
Intensely bubbling surfaces�-
Media which are very inhomogeneous, separate from each other thus forming-
separation layers (e�g� oil layer on water)�
Check the function by an application test�
In case of signal loss, the unit displays [E�033] and switches the outputs to a
definedstate(→11.5).
The unit is not suitable for applications where the probe is subjected to per-•
manent and high mechanical stress (e�g� strongly moving viscous media or
strongly flowing media)�
In case of operation with single probe: use preferably in metal tanks� When•
installed in plastic tanks, deterioration caused by electromagnetic interference
mayoccur(noiseimmunitytoEN61000-6-2).Remedy:→6.4.2.
In case of operation with coaxial probe: not suitable for viscous media and•
media prone to formation of deposit�

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Function5
Measuring principle5.1
The unit operates to the principle of
guided wave radar� It measures the
level using electromagnetic pulses in
the nanosecond range�
The pulses are transmitted by the sen-
sor head and guided along the rod (fig�
1)� When they hit the medium to be
detected they are reflected and guided
back to the sensor (fig� 2)� The time
between transmitting and receiving the
pulse directly relates to the travelled
distance (D) and the current level�
The reference for distance measure-
ment is the lower edge of the process
connection�
D
21
The figure shows operation with single
probe�
In case of operation with a coaxial probe,
the guided wave runs along the inside of
the coaxial pipe�
Features of the unit5.2
Easy set-up
When the unit is supplied with operating voltage for the first time, the probe•
length, the medium to be detected and the type of probe used must be entered�
Afterthis,theunitisoperational.(→10.2).
If necessary, parameters for the output signals and optimisation of the monitor-•
ingfunctionscanbeset(→10.3to10.5).
All settings can also be carried out before installation of the unit�•
Reset to the factory settings is possible�•
Electronic lock can be set to prevent unintentional operations�•
Display functions
The unit displays the current level, either in cm, inch or in percent of the final•
value of the measuring range� Factory setting: cm� The display unit is defined
byprogramming(→10.3).IntheRunmode,itcanbetemporarilyswitched
between length indication (cm / inch) and percentage:
Press [Set] briefly�►
The selected unit is displayed for 15 s, the corresponding LED is lit�>
With each push of the button the display type is changed�

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The set unit of measurement and the switching status of the outputs are indi-•
cated by LEDs�
Analogue function
The unit provides an analogue signal proportional to level� The analogue output
(OUT2) can be set as current or voltage output:
Current output analogue 4���20 mA ([OU2] = [I]); voltage output analogue•
0���10 V ([OU2] = [U])�
The analogue start point [ASP] determines at which measured value the output•
signal is 4 mA or 0 V�
The analogue end point [AEP] determines at which measured value the output•
signal is 20 mA or 10 V�
Minimum distance between [ASP] and [AEP] = 25 % of the active zone�
Curve of the analogue signal:s (Factory setting):
I [mA]
U [V]
L
S2
S1
AI1I2
L = level
A=activezone;I1=inactivezone1;I2=inactivezone2(→12Scaledrawing)
S1 = zero signal (4 mA / 0 V); S2 = full signal (20 mA / 10 V)
Note the tolerances and accuracy limits during the evaluation of the analogue
signal(→13Technicaldata).

10
Curve of the analogue signal: (Measuring range scaled):
I [mA]
U [V]
L
S2
S1
A
ASP AEP
I1I2
L = level; ASP = analogue start point; AEP = analogue end point
A=activezone;I1=inactivezone1;I2=inactivezone2(→12Scaledrawing)
S1 = zero signal (4 mA / 0 V); S2 = full signal (20 mA / 10 V)
Note the tolerances and accuracy limits during the evaluation of the analogue
signal(→13Technicaldata).
Switching functions
The unit signals via the switching output OUT1 that a set limit level has been
reached or that the level is below the limit value�
For the output the following switching functions can be selected:
Hysteresis function / normally open (figure 1): [OU1] = [Hno]�•
Hysteresis function / normally closed (figure 1): [OU1] = [Hnc]�•
First the set point (SP1) is set, then the reset point (rP1) with the requested
difference�
Window function / normally open (figure 2): [OU1] = [Fno]�•
Window function / normally closed (figure 2): [OU1] = [Fnc]�•
The width of the window can be set by means of the difference between FH1
and FL1� FH1 = upper value, FL1 = lower value�

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UK
t
L
FH
FL
1
0
1
0
FE
Fno
Fnc
1 2
L = level; HY = hysteresis; FE = window
For the switching output a switch-off delay of max� 5 s can be set (e�g� for•
especially long pump cycles)�
Offset for indicating the real level in the tank
The zone between tank bottom and lower edge of the probe can be entered as
offset value [OFS]� So display and switch points refer to the actual level�
Probes for different tank heights
The unit can be installed in tanks of different sizes� Probes in different lengths•
are available� To adapt to the tank height, each probe can be shortened� The
minimum probe length is 10 cm, the maximum probe length is 160 cm�
Probe and housing can be rotated without restriction� This enables easy instal-•
lation and orientation of the head of the unit after installation�
Safe state
In case of a fault a safe state can be defined for each output�•
If a fault is detected or if the signal quality is below a minimum value, the out-•
puts pass into the "safe state"� For this case the response of the outputs can be
set via the parameters [FOU1], [FOU2]�
Temporary loss of signal caused e�g� by turbulence or foam formation can•
besuppressedbyadelaytime(→10.5.8[dFo]).Duringthedelaytimethe
last measured value is frozen� If the measured signal is received again with
sufficient strength within the delay time, the unit continues to work in normal
operation� If, however, it is not received again with sufficient strength within the
delay time, the outputs pass into the safe state�

12
Installation6
Installation location / environment6.1
Vertical installation from the top is preferred�•
Unit with single probe6.1.1
Forasafefunction,theunitrequiresalaunchingplate(→6.4).•
For optimum operation the unit should be installed as near as possible to•
the tank wall� Distance between the rod and the tank wall: minimum 40 mm,
maximum 300 mm�
The following minimum distances between the rod and tank walls, objects in•
the tank (B), tank bottom and other level sensors must be adhered to:
50mm
10mm
100mm
B40mm
For tank walls which are not straight, steps, supports or other structures in the•
tank a distance of 50 mm to the tank wall must be adhered to�
For rod lengths > 70 cm the rod can be considerably deflected by movement of•
the medium� To avoid contacting the tank wall or other structures in the tank in
such cases, the minimum distances should be increased� Reference values:
Rod length Distance to the tank wall or structures in the tank
70���100 cm 100 mm
100���160 cm 180 mm
If the medium is strongly polluted, there is the risk that a bridge forms between•
the rod and the tank wall or structures in the tank� To avoid incorrect meas-
urements: adhere to increased minimum distances depending on type and
intensity of the soiling�

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UK
For installation in pipes:•
The inside pipe diameter (d) must be at least 100 mm�-
Only install the unit in metal pipes�-
For installation in connection pieces:•
The diameter of the connection piece (d) must be at least 50 mm�-
The height of the connection piece (h) must not exceed 40 mm�-
d
d
h
The maximum level must not ex-•
ceed the limit of the block distance
(BD = 30 mm)� If it is exceeded by
more than 10 mm, malfunctions
can occur�
Remedies: arrange for a spout; in-
stall the unit in a connection piece�
BD
Do not install the unit in the immediate vicinity of a fill opening� If possible,•
install a fill pipe (A) in the tank� Minimum distance between the fill pipe and the
rod=50mm;higherforrodlengths>70cmandincaseofheavysoiling(→
6�1�1)�

14
50mm
A
Strong foam formation and strongly moving surfaces can lead to malfunctions�•
Recommended remedies: use a coaxial probe, install a still pipe or bypass�
Note: minimum diameter d = 100 mm� The upper access to the bypass (A) and
the fill openings of the still pipe (B) must be above the maximum level� The
lower edges of the bypass (C) and of the still pipe (D) must be below the mini-
mum level� This ensures that neither foam nor waves impact the sensor zone�
d
d
AB
CD

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UK
Unit with coaxial probe6.1.2
There are no minimum distances•
to the tank wall and the baffles (B)
required�
Minimum distance to the bottom of•
the tank: 10 mm�
The vent hole (A) must not be•
covered by mounting elements or
similar�
Do not install the unit in the im-•
mediate vicinity of a fill opening� No
water jets must enter into the holes
of the coaxial pipe�
A
B
10mm
Note in case of foam formation: the vent of the coaxial pipe must be above•
the maximum level� The lowest opening of the coaxial pipe must be below the
minimum level�
Installation of the probe6.2
Rod and coaxial pipe are not included in the scope of delivery� They must be
orderedseparately(→3Itemssupplied).
Installation of the rod6.2.1
Fixing of the rod:
Screw the rod to the unit and tighten►
it�
Recommended tightening torque:
4 Nm�
For ease of installation and removal
the rod connection can be rotated with-
out restriction� Even if rotated several
times there is no risk of damage to the
unit�
6
Lmin
L
Lmin = 10 cm
In case of high mechanical stress (strong vibration, moving viscous media) it may
be necessary to secure the screw connection, e�g� by a screw retaining com-

16
pound� Note: such substances may migrate into the medium� Make sure that they
are harmless�
When using mechanical means of securing (e�g� tooth lock washer), protruding
edges must be avoided� They may cause interference reflection�
Installation of the coaxial pipe6.2.2
(only necessary if the unit is to be operated with coaxial probe)
The coaxial pipe and the rod must be of the same end length� The coaxial
pipecanbeshortened(→6.3.2).
Screw the rod to the unit and tighten►
it� Recommended tightening torque:
4 Nm�
Slide the sensor sealing (A) onto►
the thread�
Slide the coaxial pipe (B) onto the►
rod� Carefully center it and carefully
move the rod through the centring
piece (C) (for lengths > 140 cm
through both centring pieces) of the
coaxial pipe� Do not damage the
centring pieces�
Screw onto the sensor thread and►
tighten�
A
C
B
32
32
Shortening of the probe6.3
Shortening of the rod6.3.1
The rod can be shortened to adapt to different tank heights� NOTE: ensure that
the rod length is not below the minimum permissible length of 10 cm (Lmin)�
Proceed as follows:
Screw the rod to the unit�►
Mark the desired length (L) on the rod� The reference point is the lower edge of►
the process connection�
Remove the rod from the unit�►
Shorten the rod�►
Remove all burrs and sharp edges�►

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UK
Screw the rod to the unit again and tighten it� Recommended tightening torque:►
4 Nm�
Precisely measure the rod length L, note the value� It must be entered during►
parametersettingoftheunit(→10.2).
Shortening of the coaxial pipe6.3.2
The coaxial pipe and the rod must be of the same end length�
Remove fastening bracket and►
centring piece (A, B)�
Shorten the coaxial pipe to the►
requested length: LK= L + 9 mm�
After shortening, at least one hole
(C) for insertion of the fixing bracket
has to be left�
Remove all burrs and sharp edges�►
Insert centring piece (A) at the►
lower end of the pipe and attach it
using the fixing bracket (B) at the
lower hole (C)�
AB
C
LK= length of the coaxial pipe
L = length of the rod from the lower edge
of the process connection
Installation of the unit with single probe6.4
Installation in metal tanks6.4.1
NOTE: In all cases the unit needs a metal surface to transfer the measured sig-
nals (launching plate)� For installation in closed metal tanks, the metal lid serves
as a launching plate (R)�
2 ways of installation are possible:
Screw in a G¾ process connection in the tank lid (fig� A)�•

18
Installation in the tank lid using a flange plate e�g� for tanks with thin walls (fig�•
B)�
R
32
A
R
B
For installation in open tanks, the unit must be installed using a metal fixture� It
serves as a launching plate (R)� Minimum size: 150 x 150 mm for a square fixture,
150 mm diameter for a circular fixture� If possible, mount the unit in the middle
of the fixture� The distance D2 must not be below 40 mm (fig� C); higher for rod
lengths>70cmandincaseofheavysoiling(→6.1.1).
D2
150 mm
R
C
The lower edge of the process connec-
tion should be flush with the installa-
tion environment� Use seals or wash-
ers (D) to reach the required height�
When using the ifm flange plates flush
installation is ensured�
D

19
UK
Installation in plastic tanks6.4.2
To enable sufficient transfer of the
measured signal, note in case of
installation in plastic tanks or metal
tanks with plastic lid:
A drill hole with a minimum diam-•
eter of 150 mm must be applied to
the plastic lid�
For installation of the unit, a flange•
plate (= launching plate R) must be
used which sufficiently covers the
drill hole�
150 mm
R
Minimum distance between rod and tank wall = 80 mm, higher for rod lengths > 70
cmandincaseofheavysoiling(→6.1.1).
When installed in plastic tanks, there may be deterioration caused by
electromagnetic interference� Remedy:
Apply a metal foil to the outside of the tank�•
Apply a shielding screen between the level sensor and other electronic•
units�
Operation with coaxial probe efficiently protects the unit from elec-•
tromagnetic interference� Please note the restrictions regarding the
applicationarea(→4.3).
Installation using a flange plate6.4.3
Flange plates are not included in the scope of delivery� They must be ordered
separately(→chapter3).
d
A
B

20
Arrange for a bore hole in the tank lid� It must have a minimum diameter (d) to►
enable sufficient transfer of the measured signal to the probe� The diameter
depends on the wall thickness of the tank lid:
Wall thickness [mm] 1���5 5���8 8���11
Bore hole diameter [mm] 35 45 55
Install the flange plate with the flat surface showing to the tank and fix it with►
appropriate screws�
A seal (B) can be inserted between flange plate and tank (some flange plates
are supplied with seal)�
Ensure cleanness and evenness of the sealing areas, especially if the tank is►
under pressure� Tighten the fixing screws sufficiently�
Screw the unit in the flange plate and tighten firmly�►
Make sure that the supplied sensor seal (A) is correctly positioned�►
Installation of the unit with coaxial probe in the tank6.5
Seal the process connection�►
For pipes with G¾ process connection: slide the supplied seal onto the thread•
of the coaxial pipe�
For pipes with G¾“ NPT process connection: apply a suitable sealing material•
(e�g� Teflon tape)�
Screw the sensor with the coaxial pipe into the tank and tighten it�►
After installation, the sensor housing can be aligned� It can be rotated
without restriction� Even if rotated several times there is no risk of damage
to the unit�
Table of contents
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