PKP FOS01 User manual

PKP Prozessmesstechnik GmbH
Borsigstraße 24
D-65205 Wiesbaden- ordenstadt
Tel.: ++49-(0)6122-7055-0
Fax: ++49-(0)6122-7055-50
Email: [email protected]
Instruction Manual
FOS01
Optoelectronic Levelswitch

G
1. General information 4
2. Safety 5
3. Specifications 9
4. Design and function 10
5. Transport, pac aging and storage 11
6. Commissioning, operation 12
7. Maintenance and cleaning 13
8. Faults 14
9. Warranty 15
10. Dismounting, return and disposal 15
Table of Contents

1. General information
■ The mini limit switch described in the operating instructions has been manufactured
using state-of-the-art technology.
All components are subject to stringent quality and environmental criteria during
production. Our management systems are certified to I O 9001.
■ These operating instructions contain important information on handling the mini limit
switch. Working safely requires that all safety instructions and work instructions are
observed.
■ Observe the relevant local accident prevention regulations and general safety
regulations for the mini limit switch's range of use.
■ The operating instructions are part of the instrument and must be kept in the immediate
vicinity of the mini limit switch and readily accessible to skilled personnel at any time.
■ killed personnel must have carefully read and understood the operating instructions,
prior to beginning any work.
■ The manufacturer's liability is void in the case of any damage caused by using the
product contrary to its intended use, non-compliance with these operating instructions,
assignment of insufficiently qualified skilled personnel or unauthorised modifications to
the mini limit switch.
■ The general terms and conditions contained in the sales documentation, shall apply.
■ ubject to technical modifications.
■ Further information:
- Internet address: www.pkp.de
- Application concultant: Tel.: (+49) 6122 – 70 55 0
Fax: (+49) 6122 – 70 55 50
E-Mail: [email protected]
Explanation of symbols
WARNING!
... indicates a potentially dangerous situation, which can result in serious
injury or death, if not avoided.
CAUTION!
... indicates a potentially dangerous situation, which can result in light injuries
or damage to equipment or the environment, if not avoided.

Information
... points out useful tips, recommendations and information for efficient and
trouble-free operation.
DANGER!
...identifies hazards caused by electric power. hould the safety instructions
not be observed, there is a risk of serious or fatal injury.
WARNING!
... indicates a potentially dangerous situation that can result in burns, caused
by hot surfaces or liquids, if not avoided.
2. Saf ty
WARNING!
Before installation, commissioning and operation, ensure that the appropriate
instrument has been selected in terms of measuring range, design and
specific measuring conditions.
Non-observance can result in serious injury and/or damage to equipment.
Further important safety instructions can be found in the individual chapters of
these operating instructions.
2.1 Int nd d us
This instrument is designed to detect limit levels of liquids. The values given in chapter
"3. pecifications" must not be exceeded. The mini limit switch is not suitable for milky,
turbid, outgassing, sticky and crystallising media.
The mini limit switch has been designed and built solely for the intended use described
here, and may only be used accordingly.
The technical specifications contained in these operating instructions must be observed.
Improper handling or operation of the mini limit switch outside of its technical specifications
requires the instrument to be shut down immediately.

The manufacturer shall not be liable for claims of any type based on operation contrary to
the intended use.
2.2 P rsonn l qualification
WARNING!
Risk of injury should qualification b insuffici nt!
Improper handling can result in considerable injury and damage to equipment.
■ The activities described in these operating instructions may only be carried
out by skilled personnel who have the qualifications described below.
■ Keep unqualified personnel away from hazardous areas.
Skill d p rsonn l
killed personnel are understood to be personnel who, based on their technical training,
knowledge of measurement and control technology and on their experience and
knowledge of country-specific regulations, current standards and directives, are capable of
carrying out the work described and independently recognising potential hazards.
pecial operating conditions require further appropriate knowledge, e.g. of aggressive
media.
2.3 Sp cial hazards
WARNING!
For hazardous media such as oxygen, acetylene, flammable or toxic gases or
liquids, and refrigeration plants, compressors, etc., in addition to all stand-
ard regulations, the appropriate existing codes or regulations must also be
followed.
WARNING!
To ensure safe working on the instrument, the operating company must
ensure
■ that suitable first-aid equipment is available and aid is provided whenever
required.
■ that the operating personnel are regularly instructed in all topics regarding
work safety, first aid and environmental protection and knows the operating
instructions and, in particular, the safety instructions contained therein.

DANGER!
Danger of death caused by electric current
Upon contact with live parts, there is a direct danger of death.
■ Electrical instruments may only be installed and mounted by skilled
electrical personnel.
■ Operation using a defective power supply unit (e.g. short circuit from the
mains voltage to the output voltage) may result in life-threatening voltages
on the instrument!
WARNING!
Residual media in dismounted instruments may result in a risk to people, the
environment and the system. Take sufficient precautionary measures.
Do not use this instrument in safety or Emergency top devices. Incorrect use
of the instrument can result in injury.
hould a failure occur, aggressive media with extremely high temperature and
under high pressure or vacuum may be present at the instrument.
CE, Communauté Europé nn
Instruments bearing this mark comply with the relevant European directives.

3. Specifications
General Data
M asuring accuracy ±0.5 mm
Ambi nt light max. 10,000 Lux (immersed)
Mounting position any
W ight 0.15 kg
Design Data
M dium t mp ratur -30 ... +140 °C
Ambi nt t mp ratur -25 ... +70 °C
Working pr ssur 0 ... 5 MPa (0 ... 50 bar)
M asuring l ngth see drawing on page 9
Proc ss conn ction G ½ A, M16 x 1.5, ½ NPT etc. see drawings
Mat rials
■ ensor
■ Tip
■ Electronics housing
tainless steel 1.4571
Quartz
tainless steel 1.4301
Electrical Data
Supply voltag DC 24 V -25 ... +30 %
Supply curr nt max. 40 mA
Pow r consumption 1 W
Output
■ Voltage
■ Current
■ other
DC 24 V
0.5 A at Tu 70 °C
short-circuit protection, reverse voltage protection,
current, voltage and power limitation
Switching curr nt
(Tu = 70 °C)
0.5 A
El ctrical conn ction ■ PVC cable 3 x 0.14 mm²
■ Plug 4-pole series 713, M12
Ingr ss prot ction
■ With plug
■ With cable
IP 65 per EN 60 529
IP 66 per EN 60 529

Proc ss conn ction
Ø A
Spann r width
B
S aling fac
Ø C
M16 x 1.5 W24 Ø 21
G ½ A W30 Ø 26
½ NPT W24 -
4. Design and function
4.1 Description
This instrument is designed to detect limit levels of
liquids. For this purpose the sensor is equipped with a
V-shaped glass-tip. The model is also ideally suited for
level control, particularly in applications requiring high
precision. The measurement principle is independent of
the colour, refractive index, density, conductance and
dielectric constant of the liquid.
Integrated electronics include limit sensing and self-
calibration. The output is an open-collector pnp-transistor.
4.2 Instrum nt d sign
The sensor is a one-piece device consisting of a mechanical connection which depends
on the type of sensor, and integrated electronics built into a stainless steel housing. The
measuring length, ML, to the sealing face is always 24 mm.
Dim nsions in mm
Principle of operation
Gas
Liquid
Plug conn ction
cable
length
3000
green
LED
Mod l with cabl conn ction
4.3 Scop of d liv ry
Cross-check scope of delivery with delivery note.
S l ctabl proc ss conn ctions

5. Transport, packaging and storage
5.1 Transport
Check instrument for any damage that may have been caused by transport.
Obvious damage must be reported immediately.
5.2 Packaging
Do not remove packaging until just before mounting.
Keep the packaging as it will provide optimum protection during transport (e.g. change in
installation site, sending for repair).
5.3 Storag
P rmissibl conditions at th plac of storag :
■ torage temperature: -25 ... +70 °C
■ Humidity: 35 ... 85 % relative humidity (no condensation)
Avoidanc of xposur to th following factors:
■ Proximity to hot objects
■ Mechanical vibration, mechanical shock (putting it down hard)
■ oot, vapour, dust and corrosive gases
■ Potentially explosive environments, flammable atmospheres
tore the instrument in its original packaging in a location that fulfills the conditions listed
above. If the original packaging is not available, package and store the instrument as
described below:
1. Wrap the instrument in an antistatic plastic film.
2. Place the instrument, along with shock-absorbent material, in the packaging.
3. If stored for a prolonged period of time (more than 30 days), place a bag, containing a
desiccant, inside the packaging.
WARNING!
Before storing the instrument (following operation), remove any residual
media. This is of particular importance if the medium is hazardous to health,
e.g. caustic, toxic, carcinogenic, radioactive, etc.

6. ommissioning, operation
When unpacking the mini limit switch check all items for external damage. A functional
test may be carried out prior to the installation. To do this, the device should be temporarily
connected and the sensor-tip immersed in and then withdrawn from a glass of water.
WARNING!
The electrical connection must only be carried out by qualified skilled
personnel. Observe the relevant VDE regulations.
6.1. Installation instructions
tank or pipe wall
rubber or metal seal
welded adapter
ATTENTION!
In the case of
electropolished pipes
min. distance can be
much larger than 10 mm.
long adapter
Insulation
horizontal installation v rtical installation
inclin d installation high-t mp ratur m dium

6.2 M chanical installation of th Mini Limit Switch
Mount the mini limit switch, pressure tight, into the process connection. The distance
between sensor-tip and opposite surface of the pipe should be greater than 10 mm. If the
pipe is electropolished, the distance should be increased accordingly.
6.3. El ctrical conn ction of th mini limit switch
The sensor must be connected as shown in the connection diagram.
El ctrical conn ction diagram
Connector assignment
Output
Output
brown
green
white
O. C. pnp Load
Switching dir ction
The switching direction is factory set:
Mod l Function Condition LED Output transistor Ext. r lay
E Normally
open
immersed on switch on connect
E Normally
open
not immersed off switch off disconnect
A Normally
closed
immersed off switch off disconnect
A Normally
closed
not immersed on switch on connect
7. Maint nanc and cl aning
7.1 Maint nanc
As a rule, the Mini Limit witch is maintenance-free.
If the plant is subject to heavy contamination or scale, it is advisable to set up periodic
maintenance. This depends on the optical condition of the glass tip and the switch
operation.
Repairs must only be carried out by the manufacturer.

7.2 Cl aning
CAUTION!
■ Before cleaning, correctly disconnect the instrument from the pressure
supply, switch it off and disconnect it from the mains.
■ Clean the instrument with a moist cloth.
■ Electrical connections must not come into contact with moisture.
■ Wash or clean the dismounted instrument before returning it, in order to
protect staff and the environment from exposure to residual media.
■ Residual media in dismounted instruments can result in a risk to persons,
the environment and equipment. Take sufficient precautionary measures.
For information on returning the instrument see chapter "10.2 Return".
8. Faults
Faults Possibl caus s M asur s
No function No power supply Measure power supply, check
connection to cable or plug
No function in spite of
liquid level change
Contamination or scale on
the glass-tip
Clean glass-tip (set up periodic
maintenance)
ensor works to reverse
logic
A instead of E or E
instead of A specified
Change sensor
CAUTION!
If faults cannot be eliminated by means of the measures listed above, the
instrument must be shut down immediately, and it must be ensured that
pressure and/or signal are no longer present, and it must be prevented from
being inadvertently put back into service.
In this case, contact the manufacturer.
If a return is needed, please follow the instructions given in chapter
"10.2 Return".

9. Warranty
The warranty period is 24 months.
Under the condition that this Mini Limit witch has been handled and operated in
accordance with these operating instructions. For consumable and spare parts the warranty
is restricted to faults in material or construction.
10. Dismounting, r turn and disposal
WARNING!
Residual media in dismounted instruments can result in a risk to persons, the
environment and equipment. Take sufficient precautionary measures.
10.1 Dismounting
WARNING!
Risk of burns!
Let the instrument cool down sufficiently before dismounting it!
When dismounting it, there is a risk that dangerously hot pressure media may
escape.
Only disconnect the mini limit switch once the system has been depressurised!
10.2 R turn
WARNING!
Absolut ly obs rv wh n shipping th instrum nt:
All instruments delivered to PKP Prozessmesstechnik GmbH must be free
from any kind of hazardous substances (acids, bases, solutions, etc.).
When returning the instrument, use the original packaging or a suitable transport package.
To avoid damag :
1. Wrap the instrument in an antistatic plastic film.
2. Place the instrument, along with the shock-absorbent material, in the packaging.
Place shock-absorbent material evenly on all sides of the shipping box.
3. If possible, place a bag, containing a desiccant, inside the packaging.
4. Label the shipment as transport of a highly sensitive measuring instrument.
10.3 Disposal
Incorrect disposal can put the environment at risk.
Dispose of instrument components and packaging materials in an environmentally
compatible way and in accordance with the country-specific waste disposal regulations.

Flow Measurement and Monitoring
FOS01
Optoelectronic
Level Switch
•for liquids
•small and compact, no mechanics
•easy installation
•switching status indication by L D
•low maintenance
•max. pressure: 50 bar
•max. temperature: 135 °C
Description:
An optical sensor is mounted in a robust stainless steel
housing. It consists of a quartz glass tip with an infrared diode
as transmitter and a light-sensitive semiconductor as receiver.
If no liquid wets the sensor tip, the infrared light is completely
reflected from the inside of the quartz glass.
However, as soon as it is immersed in the medium, a large
part of the transmitted light can be escape into the liquid. This
is registered by the receiver, which then initiates a switching
process at the N transistor output of the device, which is
indicated directly by a green LED.
Typical applications:
The field of application for optoelectronic level indicators is the
detection of limit values in a large number of liquids. The
advantage here is that the measurement method is largely
independent of physical variables such as refractive index,
color, density, dielectric constant or conductivity. The very
compact design guarantees minimal space requirements,
making measurement in very small volumes possible. The
arbitrary mounting position as well as the high pressure and
temperature ranges offer a wide range of applications.
PKP Prozessmesstechnik GmbH
Borsigstr. 24 • D-65205 Wiesbaden
S [phone] • T [phone]
[email protected] • www.pkp.de
20190907

Models:
FOS01 Optoelectronic level s itch
Process connection:
G 1/2 A threaded connection (standard)
optional: M16 x 1,5 and 1/2" N T
Electrical connection:
3 m VC cable (standard)
optional: plug connection Binder 713 available.
Output:
The factory setting of the switch is either immersion or
submersible.
Sensor housing material:
The switch housing material is always stainless steel 1.4301, the
sensor housing is optionally available in various stainless steels.
Technical Data:
Max. pressure: 0 to 50 bar
Max. media temp.: −30 °C to +135 °C
Max. ambient temp.: −25 °C to +70 °C
S itch housings: stainless steel 1.4301
Sensor housings: stainless steel 1.4301,
1.4541 or 1.4571
Light conductor: quartz glass
Gasket: graphite / TFE
S itch status display: green LED
Weight: 0,10 kg to 0,15 kg
Precision: ± 0,5 mm
Light source: IR light 930 nm
Ambient light: max. 10.000 Lux
Min. distance to an
opposite surface: >10 mm
> 20 mm if electropolished
Mounting position: any
Dimensions:
Order Code:
Order number: FOS01.
Optoelectronic level s itch
3. 2. 1. 1. 0
Process connection:
1 = M16 x 1,5
2 = 1/2" N T (with cable connection only)
3 = G 1/2 A (standard)
Electrical connection:
1 = 3 m cable VC
2 = round plug M12x1
Output:
1 = immersion switching
(N/O with rising level)
2 = submerging switching
Sensor housing material:
1 = stainless steel 1.4571
Options:
0 = without
9 = please specify in plain text
Accessory:
SM12: M12 connector plug with
VC- cable
lectrical Data:
Po er supply: 24 VDC ± 30 %
Current consumption: max. 40 mA
Output: N open collector, short-circuit-
proof, current, voltage and
power limitation
S itching current: (Tu = 70 °C): 0,5 A
Connection: VC cable 3 x 0,14 mm² or
plug 4-pole acc. to DIN 41524
Protection class: I 66 acc. to EN 60529 with cable,
I 65 acc. to EN 60529 with plug
lectrical Connection:
Pin assignment:
PKP Prozessmesstechnik GmbH
Borsigstr. 24 • D-65205 Wiesbaden
S [phone] • T [phone]
[email protected] • www.pkp.de
Level