Pepperl+Fuchs KVF-104-PF User manual

0102
ISO9001
KVF-104-PF
LAYER THICKNESS SENSOR
SCHICHTDICKENSENSOR
DÉTECTEUR D'ÉPAISSEUR DE COUCHE
LAGTYKKELSESFØLER
PROCESS AUTOMATION
MANUAL

With regard to the supply of products, the current issue of the following docu-
ment is applicable: The General Terms of Delivery for Products and Services of
the Electrical Industry, published by the Central Association of the Electrical In-
dustry (Zentralverband Elektrotechnik und Elektroindustrie (ZVEI) e.V.) in its
most recent version as well as the supplementary clause: "Expanded reserva-
tion of proprietorship"
Es gelten die Allgemeinen Lieferbedingungen für Erzeugnisse und Leistungen
der Elektroindustrie, herausgegeben vom Zentralverband Elektroindustrie
(ZVEI) e.V. in ihrer neusten Fassung sowie die Ergänzungsklausel: "Erweiterter
Eigentumsvorbehalt".
Les conditions de vente générales pour les produits et les services de l'industrie
des équipements électriques publiées par la Fédération de l'industrie électron-
ique (ZVEI) s'appliquent dans leur toute dernière version, tout comme la clause
complémentaire "Réserve de propriété élargie".
De almene leveringsbetingelser for produkter og ydelser fra elektronikindus-
trien, der er udgivet af Zentralverband Elektroindustrie (ZVEI) e.V. i den seneste
udgave samt tillægsklasulen: "Udvidet ejendomforbehold" er gældende".
LAYER THICKNESS SENSOR

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1 Safety .............................................................................3
1.1 General .........................................................................................................3
1.2 Used Symbols..............................................................................................3
1.3 Declaration of Conformity ..........................................................................4
1.4 Intended use ................................................................................................4
1.4.1 Coding ...........................................................................................................4
1.5 Delivery, Transport and Storage.................................................................5
1.6 Installation and Commissioning ................................................................5
1.6.1 Installation of the sensor ...............................................................................5
1.6.2 Installation in connection with intrinsically safe circuits .................................5
1.6.3 Sensor cable .................................................................................................6
1.7 Operation .....................................................................................................6
1.7.1 Caution - emulsions.......................................................................................6
1.8 Maintenance.................................................................................................6
1.9 Repair ...........................................................................................................6
1.10 Disposal .......................................................................................................6
1.11 Applied standards and directives..............................................................7
2 Product Specifications .................................................8
2.1 Function .......................................................................................................8
2.2 Layout and dimensions ..............................................................................8
2.3 Product program .........................................................................................9
3 Installation................................................................... 10
3.1 Mounting in oil/petrol separators............................................................. 10
3.2 Connection ................................................................................................ 11
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4 Operation......................................................................12
4.1 Emptying (disposal) of the container.......................................................12
5 Maintenance and repair ..............................................13
5.1 Sensor test .................................................................................................13
6 Troubleshooting ..........................................................14
6.1 System care................................................................................................14
7 Technical specifications.............................................15

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Safety
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1 Safety
1.1 General
The operator of the system is responsible in terms of planning, mounting, commissioning,
operating and maintenance.
Installation and commissioning of all devices must be performed by a trained professional only.
Protection of operating personnel and the system is not ensured if the product is not used in
accordance with its intended purpose.
Laws and regulations applicable to the usage or planned purpose of usage must be observed.
Devices are only approved for proper usage in accordance with intended purpose. Improper
handling will result in voiding of any warrantee or manufacturer's responsibility.
The Declaration of Conformity, Certificate of Compliance, Statement of Conformity, EC-type-
examination certificate and data sheets are an integral part of this document.
The data sheet contains the electrical data of the Declaration of Conformity, the Certificate of
Compliance and the EC-type-examination certificate.
The documents mentioned are available from http://www.pepperl-fuchs.com or contact your
local Pepperl+Fuchs representative.
1.2 Used Symbols
Safety-relevant Symbols
Danger!
This symbol indicates a warning about a possible danger.
In the event the warning is ignored, the consequences may range from personal injury to death.
Warning!
This symbol indicates a warning about a possible fault or danger.
In the event the warning is ignored, the consequences may course personal injury or heaviest
property damage.
Caution!
This symbol warns of a possible fault.
Failure to observe the instructions given in this warning may result in the devices and any
connected facilities or systems develop a fault or fail completely.
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Safety
EN
Informative Symbols
Action
This symbol marks an acting paragraph.
1.3 Declaration of Conformity
All products have been developed and manufactured taking into consideration applicable
European standards and regulations.
The manufacturer of this product, Pepperl+Fuchs GmbH in D-68301 Mannheim, Germany, has
a certified quality assurance system in conformity with ISO 9001.
1.4 Intended use
The layer thickness sensor KVF-104-PF (referred to as "sensor" in the following section) is a
suspended sensor for monitoring oil layer thickness in oil/petrol separators.
The KVF-104-PF must always be connected to an ATEX-approved, intrinsically safe warning
device of type LAL-SRW (see product program).
1.4.1 Coding
Note!
This symbol brings important information to your attention.
Note!
A Declaration of Conformity can be requested from the manufacturer.
ISO9001
Pepperl+Fuchs GmbH
68301 Mannheim/Germany
Layer thickness sensor KVF-104-PF
DEMKO 07 ATEX 142586X
II 1G Ex ia IIB T3

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Safety
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1.5 Delivery, Transport and Storage
Check the packaging and contents for damage. In the event of damage, notify the postal
service or express agent and inform the supplier.
Check the scope of supply for completeness and correctness using the order and delivery
papers.
Keep the original packaging.
The device should always be stored or transported in the original packaging.
Always store the device in a dry and clean environment. Observe the permissible storage
temperature (see data sheet).
1.6 Installation and Commissioning
1.6.1 Installation of the sensor
The sensor may be installed in potentially explosive zone 0 in accordance with Directive
94/9/EC (ATEX). The sensor must not be installed in places with potentially aggressive vapors.
The sensor and warning device must be free of voltage during installation and maintenance.
The warning device must only be connected to the supply voltage after complete mounting and
connection of the sensors.
The cable and the identification plate attached to it are elements of the product. The cable must
not be shortened to such an extent that the identification plate is removed. The identification
plate must not be removed.
The sensor has IP68 protection and is weather- and oil-resistant. It can therefore be installed in
oil/petrol separators.
When installing the device in oil/petrol separators, observe the permissible ambient
temperature in the range from -20 °C...60°C (253 K ... 333 K).
1.6.2 Installation in connection with intrinsically safe circuits
Installation of the intrinsically safe power circuits of the devices is permitted in potentially
explosive zones, whereby, in particular, safe separation from all non-intrinsically safe power
circuits must be guaranteed.
The intrinsically safe current circuits must be installed according to valid setup regulations.
For the interconnection of the intrinsically safe field devices and the intrinsically safe power
circuits of the associated devices, the respective maximum values of the field device and the
associated device with regard to explosion protection must be observed (proof of intrinsic
safety). EN 60079-14/IEC 60079-14 must be observed.

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Safety
EN
1.6.3 Sensor cable
Sensor cables must not be installed in cable or conductor bundles together with other current
circuits. Avoid installing sensor cables parallel to other cables that may transmit interfering
signals, which impair the sensor signal and thus the alarm function. The sensor itself must not
be grounded.
If you extend the sensor cable, observe the applicable ATEX specifications with regard to color,
quality and constancy. Use an unscreened cable with a conductor size of 1 mm².
1. 7 O p e r a t i o n
1.7.1 Caution - emulsions
An oil/petrol separator is a device for separating oil from water. Situations may arise in which
the oil can not be separated because an emulsion has formed. An emulsion is a relatively
stable mixture of oil and water. Sensors can not detect oil if emulsions with a high water content
have formed. Always contact the oil/petrol separator manufacturer if there is any doubt as to
whether the oil has been separated from the water before the liquid is drained to the sewage
system.
1.8 Maintenance
For operation of oil/petrol separators, there may be standards, directives or laws that define
regular system or sensor tests. Check the operation of the sensor at least twice a year and
more frequently in the event of unfavorable environmental conditions.
When the oil/petrol separator is being emptied (disposal), the sensor must always be washed
and dried. The sensor must not be cleaned with caustic fluids. A badly contaminated sensor
can trip a wrong alarm or, in certain circumstances, fail to trip an alarm.
1.9 Repair
The devices may not be repaired, changed or manipulated. If there is a defect, the product
must always be replaced with an original part.
1.10 Disposal
Disposal of devices and their packaging material must be performed in compliance with the
applicable laws and guidelines of the corresponding country.
The devices do not contain batteries which need to be disposed of separately from the
products.

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Safety
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1.11 Applied standards and directives
EN 50020
EN 50178
EN 60079-0
EN 60079-14
EN 60079-26
EN 61000-6-2
EN 61000-6-3
ATEX Directive 94/9/EC
EMC Directive 89/336/EEC
Low Voltage Directive 73/23/EEC

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Product Specifications
EN
2 Product Specifications
2.1 Function
The sensor has an integrated electronic circuit which, via an oscillator circuit, emits a weak HF
signal that changes depending on whether the sensor element is surrounded by water or by
oil/air. The sensor is capable of distinguishing between air and water, and between water and
oil, but not between air and oil.
2.2 Layout and dimensions
The sensor consists of three sections (see illustration):
• The lower stainless steel section (1) provides electrical connection to the liquid.
• The middle section (2) is electrically isolated.
• The upper section made of stainless steel forms the switch contact (3).
The sensor has a 5-m long oil-resistant cable (4) on which the identification plate is located.
1Lower section
2Middle section
3Upper section
4Cable with identification plate
5Switch point
3
1
5
4
2
138
25
Ø31.6
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Product Specifications
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2.3 Product program
Warning device
Sensors
Accessories
Description Type code
Intrinsically safe warning device, 230 V AC LAL-SRW
Description Type code
Overflow sensor for detecting excessively high fluid level NVF-104/34-PF
Layer thickness sensor for detecting thickness of oil layer KVF-104-PF
Description Type code
Cable connector IP67 for one sensor NVO5-SK3
Mounting set for one sensor NVO5-B

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Installation
EN
3 Installation
3.1 Mounting in oil/petrol separators
Read the chapter on Safety and, in particular, the section on Installation and Commissioning
(see chapter 1.6.1) before installing the sensor. Do not remove the identification plate.
During installation, observe the instructions of the oil/petrol separator manufacturer. Always
ensure that the sensor suspension device remains constantly at the correct height. If possible,
ensure that the suspension device is mounted in a location that can be reached from the
separator access shaft so that it is possible to raise the sensor during separator emptying
(disposal) or maintenance of the oil/petrol separator.
With a correct fluid level, the sensor must be immersed a few centimeters in the fluid. How far it
is immersed depends on the type of oil/petrol separator, the design and the capacity. The lower
section made of stainless steel must always be immersed in the fluid. The switch point (see
chapter 2.2, dimension drawing, position 5) of the sensor is located between the isolated
middle section and the upper metal section.
Warning!
Risk of short circuit
Injuries and damage to the device are possible when working with live parts.
• Before working on the device, always disconnect the supply voltage.
• Connect the device to the supply voltage only after completion of the work.
Layer thickness sensor

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3.2 Connection
Read the chapter on Safety and, in particular, the section on Installation and Commissioning
(see chapter 1.6.1) before connecting the sensor. Do not remove the identification plate.
When making the connection, ensure the polarity of the sensor cables is correct. The loop
resistance of the extension cable should not exceed 20 Ωfor the sensor.
1Layer thickness
2Alarm level
3Sensor KVF-104-PF (new model)
4Sensor KVF-103-PF (old model)
5Water
6Oil
1
2
3
5
6
4
Warning!
Risk of short circuit
Injuries and damage to the device are possible when working with live parts.
• Before working on the device, always disconnect the supply voltage.
• Connect the device to the supply voltage only after completion of the work.
Note!
Further information on connection of the sensors to the warning device is available in the
manual of the warning device LAL-SRW.

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Operation
EN
4 Operation
4.1 Emptying (disposal) of the container
The sensor is a sensitive component. Therefore always observe the following safety
information during emptying (disposal):
Caution!
Malfunction or damage through mechanical stress of the sensor.
In case of nonobservance, the safety and operation of the sensor or the entire alarm system is
not guaranteed.
• Before emptying (disposal) the oil/petrol separator, remove the sensor from the container.
• Protect the sensor against impacts, knocks and unnecessary tensile forces in the cable.
• Insert the sensor in the oil/petrol separator only after it has been filled.
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Maintenance and repair
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5 Maintenance and repair
5.1 Sensor test
Test frequency
The sensor is maintenance-free. However, to guarantee perfect operation of the complete
alarm system check the operation of the sensor at least twice a year, or more frequently in the
event of unfavorable environmental conditions.
Check of normal situation
1. Remove the sensor from the oil/petrol separator.
2. Wash and dry the sensor.
3. Take the sensor in your hand (without gloves).
4. Only touch the upper and lower metal section (see chapter 2.2, dimension drawing,
position 3 and 4)
The green "SYSTEM OK" LED lights up or flashes at the warning device.
Check of alarm situation
1. Remove the sensor from the oil/petrol separator.
2. Wash and dry the sensor.
3. Suspend the sensor freely in midair.
The "HIGH OIL LEVEL" LED lights up and, if applicable, an acoustic signal sounds.
Note!
Further information on the LED alarm messages is available in the manual of the warning
device LAL-SRW.
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Troubleshooting
EN
6 Troubleshooting
6.1 System care
Contaminated sensors can trip incorrect alarms. Clean, in particular, the sensor tips with fat
dissolving cleaning agent to remove all oil, petrol and other contamination residue.
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Technical specifications
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7 Technical specifications
Power supply Rated voltage 13 V DC
Environmental conditions Ambient temperature -20 °C ... 60 °C
(253 K ... 333 K)
Mechanical data Protection class IP68
Connection cable
Material stainless steel
Cable 5 m
Mass approx. 520 g
Dimensions ∅31.6 mm x 138 mm
Data for application in
conjunction with hazardous
areas
Voltage Ui13 V
Current Ii140 mA
Power Pi1050 mW
Internal capacity Ci200 nF
Internal inductivity Li0.2 mH
Max. internal capacity Cifor
extension cable
0.1 µF
Max. internal inductivity Ci
for extension cable
0.3 mH
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Notes
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1 Sicherheit.......................................................................3
1.1 Allgemeine Sicherheitshinweise................................................................3
1.2 Verwendete Symbole ..................................................................................3
1.3 Konformitätserklärung................................................................................4
1.4 Bestimmungsgemäße Verwendung...........................................................4
1.4.1 Kennzeichnung..............................................................................................4
1.5 Lieferung, Transport und Lagerung...........................................................5
1.6 Installation und Inbetriebnahme ................................................................5
1.6.1 Installation des Sensors ................................................................................5
1.6.2 Installation in Verbindung mit eigensicheren Kreisen....................................5
1.6.3 Sensorkabel ..................................................................................................6
1.7 Betrieb ..........................................................................................................6
1.7.1 Auftreten von Emulsion .................................................................................6
1.8 Wartung........................................................................................................6
1.9 Reparatur .....................................................................................................6
1.10 Entsorgung ..................................................................................................6
1.11 Angewandte Normen und Richtlinien........................................................7
2 Produktspezifikationen ................................................8
2.1 Funktion .......................................................................................................8
2.2 Aufbau und Abmessungen.........................................................................8
2.3 Produktprogramm .......................................................................................9
3 Installation................................................................... 10
3.1 Montage in Öl-/Benzin-Abscheideranlagen ............................................ 10
3.2 Anschluss ................................................................................................. 11
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4 Betrieb ..........................................................................12
4.1 Entleeren (Entsorgen) des Behälters.......................................................12
5 Wartung und Reparatur ..............................................13
5.1 Sensorprüfung ...........................................................................................13
6 Störungsbeseitigung...................................................14
6.1 Anlagenpflege ............................................................................................14
7 Technische Daten........................................................15