RFnivo rf3000 Manual

Level limit switch
Series RF 3000
Technical Information / Instruction manual
page
Table of contents
Page
Safety notes / Technical support 2
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Introduction 3
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Applications 4
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Technical data:
Dimensions 5
Electrical data 9
Mechanical data 10
Operating conditions 11
Transport and Storage 12
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Approvals 13
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Options 13
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Mounting 14
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Electrical installation 20
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Qickstart 22
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Advanced proramming 29
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Probe modications 35
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Assembly - Remote version / FM, FMc Control Drawing 36
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Troubleshooting 37
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Maintenance 39
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Notes for use in Hazardous Locations 41
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Disposal 43
Subject to technical change. We assume no liability for typing errors.
All dimensions in mm (inch). Different variations than specied are possible.
Please contact our technical consultants.
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Level limit switch
Series RF 3000
Technical Information / Instruction manual
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Safety notes / Technical support
Notes
• Installation, maintenance and commissioning may be accomplished only by qualied technical personnel.
• The product must be used only in the manner outlined in this instruction manual.
Special attention must be paid to warnings and notes as follows:
WARNING
Relates to a caution symbol on the product: A failure to observe the necessary
precautions can result in death, serious injury and/or considerable material damage.
WARNING
Relates to a caution symbol on the product: Risk of electric shock
WARNING
A failure to observe the necessary precautions can result in death, serious injury
and/or considerable material damage.
This symbol is used, when there is no corresponding caution symbol on the product.
CAUTION A failure to observe the necessary precautions can result in considerable material
damage.
Safety symbols
In manual and on
product
Description
CAUTION: refer to accompanying documents (manual) for details.
Earth (ground) Terminal
Protective Conductor Terminal
Technical support
Please contact your local supplier (for address see www.uwt.de). Otherwise you can contact:
UWT GmbH Tel.: [phone]
Westendstr. 5 Fax: [phone]
D-87488 Betzigau [email protected]
www.uwt.de
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Series RF 3000
Technical Information / Instruction manual
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Introduction
Applications
The device is used for level monitoring in all types of contai-
ners and silos.
It can be used with all powdery and granulated bulk materials,
slurry and liquids.
The units can be delivered with Ex-approvals for use in Dust
and Gas Hazardous Areas.
A selection of elds of application:
• Building materials industry
lime, moulding sand, etc.
• Food industry
sugar, our, salt, etc.
• Plastics industry
plastics granules etc.
• Chemical industry
pigments
• Mechanical engineering
The RFnivo is normally screwed into the lateral container wall
at a position, where the material shall be measured.
The device can also be mounted from the top of the container.
In this case an extension piece is used to mount the probe
level with the height to be measured.
The length of the probe can be up to 2.5m (98.4”) with rod
extension or 20m (787") with rope extension.
The use of a sliding sleeve is recommended so that the switch
point can be changed continuously during operation of the
device.
Function
The unit detects the capacitance between the probe and
the container wall.
The performance allows to use the unit in a wide range of
even difcult applications combined with simple handling:
• Active shield technology
The powerful active shield technology allows to ignore
material build up on the probe. Even the inuence
of conductive build up on the probe is electronically
compensated and thus ignored. This allows to measure
with high sensitivity in combination with material build up.
• Self diagnostics
The unit is able to check the internal electronic for proper
functionality. This can be done by setting a frequent auto
test or by pressing a manual test button.
• Auto calibration
The unit will auto calibrate to uncovered state after rst
time power up.
It allows to set for auto recalibration to uncovered state.
This is useful in case of a covered probe during power up.
An auto recalibration is done when the probe becomes
uncovered.
• Manual recalibration to uncovered state can be done by
simply pressing a push button.
• Full manual calibration can be selected as well.
The sensitivity is preselected to work in most applications
and can be changed if required.
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Series RF 3000
Technical Information / Instruction manual
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Applications
RF 3100 RF 3200 RF 3300
Inactive length to reach distance from silo wall • • •
Inactive length due to long mounting nozzle • • •
Full detector with short length • • •
Demand detector with short length, observe max. load • • •
Empty detector with short length, observe max. load • • •
Application in down pipe, observe max. load • • •
Inactive length to bring active probe to required level • • •
Inactive length and sliding sleeve for adjustable height • •
Full detector, rope version • • •
Empty detector, rope version, observe max. load • • •
Inactive length due to long mounting nozzle • • •
A
B
D
F
H
J
I
G
E
C
K
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Housing versions
Standard
de
Explosionproof with
increased safety
terminal box
d
Flameproof /
explosionproof
Aluminium
Aluminium
Aluminium
Technical data - Dimensions
Plastics PA6 reinforced
no electronics
inside
electronics
inside
Remote version
Remote version exemplied with RF 3100
Angle bracket
Remote cable
Spezial triaxial cable
max. length: 20m (65ft)
min. bending radius: 50mm (2")
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Technical Information / Instruction manual
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Technical data - Dimensions
Flange
Probes
Triclamp
Rod version
Shortest length
Rod version
Inactive extension
Rope version
Inactive extension
Rope version
Shortest length
Process connections:
* Active shield
RF 3100 Standard version
Only units with rod version are avaliable with
EHEDG Certicate. On rod versions with EHEDG
Certicate the length "L" is increased by 9mm
(0.35")
Thread
G 3/4"
NPT 3/4"
Thread
(except 3/4")
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Series RF 3000
Technical Information / Instruction manual
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Technical data - Dimensions
Thread Flange
Rod version
Shortest length
Rod version
Inactive extension
Rope version
Inactive extension
Rope version
Shortest length
Process connections:
* Active shield
RF 3200 Heavy Duty version
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Technical data - Dimensions
Rod version
Shortest length
Rod version
Inactive extension
Rope version
Inactive extension
Rope version
Shortest length
Thread Flange
Process connections:
* Active shield
RF 3300 High temperature version
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Technical data - Electrical data
Electrical data
Connection terminals 0.14 - 2.5mm2 (AWG 26-14)
Cable entry M20 x 1.5 screwed cable gland
NPT 1/2“ conduit connection
NPT 3/4” conduit connection
Clamping range (diameter) of the factory provided cable glands:
M20 x 1.5: 6 .. 12mm (0.24 .. 0.47"")
Signal delay Sensor uncovered -> covered or covered -> uncovered or covered <-> uncovered:
adjustable ca. 0.5 to 60 sec
Safety operation
(FSL,FSH)
Switchable for minimum or maximum safety
Operation frequency ca. 100kHz
Overvoltage category II
Pollution degree 2 (inside housing)
Electronics Universal voltage
Relay DPDT
Power supply 21 .. 230V 50-60Hz or DC ±10%*
*incl. ±10% of EN 61010
Max. ripple of power
supply
7 Vss at DC sypply
Installed load max. 1.5VA or 1.5W
Signal output Floating relay DPDT
AC max. 250V, 8A non inductive
DC max. 30V, 5A non inductive
Display 4 digit LCD
Display of actual measured capacitance, signal
output state and self diagnostics
Min. operating temperature: -30°C (-22°F)
Indicating light Status by 3 colour built-in LED (according to NE44):
Power on, signal output, failure /maintenance
Data storage Nonvolatile EPROM for Menu settings and calibration data
Isolation Power supply to signal output: 2225Vrms
Signal output to signal output: 2225Vrms
Protection class I
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Mechanical data
Housing Aluminium, powder coated RAL 5010 gentian blue
Optional: Plastics PA6 reinforced
Seal between housig and lid: NBR
Seal between housing and process connection: NBR
Nameplate: polyester lm
Degree of protection IP 67 (EN 60529), NEMA Type 4X
Process connection
/ probes
RF 3100:
Material: Stainless steel 1.4301 (304)/1.4305 (303) or 1.4404 (316L)/1.4401(316) for rope
Probe isolation PPS reinforced
Probe gaskets FKM
Coating of probe/rope (optional) PFA
Thread: G 3/4", 1", 1¼", 1½“ DIN 228, M30x1.5, M32x1.5, NPT 3/4", 1", 1¼”, 1½“ tapered ANSI B 1.20.1
Triclamp: 1" (DN25), 1½" (DN40), 2" (DN 50) ISO 2852
RF 3200:
Material: Stainless steel 1.4301 (304)/1.4305 (303) or 1.4404 (316L)/1.4401(316) for rope
Probe isolation PPS reinforced
Probe gaskets FKM or FFKM
Thread: G 1¼, 1½“ DIN 228, NPT 1¼”, 1½“ tapered ANSI B 1.20.1
RF 3300:
Material: Stainless steel 1.4301 (304)/1.4305 (303) or 1.4404 (316L)/1.4401(316) for rope
Probe isolation ceramic
Probe gaskets graphite
Thread: G 1¼, 1½“ DIN 228, NPT 1¼”, 1½“ tapered ANSI B 1.20.1
Flanges according to selection 1.4541 (321) or 1.4404 (316L)
All material food grade
Sound level max. 40dBA
Overall weight
(ca.) Standard
housing
de-
housing
d-
housing
Basic weight* Active probe length:
L1**
Inactive length:
L2**
RF 3100
rod version
1.7 kg
(3.7 lbs)
2.7 kg
(6.0 lbs)
3.0 kg
(6.6 lbs)
+0.62 kg/m
(1.37 lbs/39.3“)
+1.2 kg/m
(2.65 lbs/39.3“)
RF 3100
rope version
2.3 kg
(5.1 lbs)
3.3 kg
(7.3 lbs)
3.6 kg
(8.0 lbs)
+0.06 kg/m
(0.13 lbs/39.3“)
+1.2 kg/m
(2.65 lbs/39.3“)
RF 3200
rod version
2.8 kg
(6.2 lbs)
3.8 kg
(8.4 lbs)
4.1 kg
(9.0 lbs)
+3.0 kg/m
(6.61 lbs/39.3“)
+3.26 kg/m
(7.19 lbs/39.3“)
RF 3200
rope version
4.0 kg
(8.8 lbs)
5.0 kg
(11 lbs)
5.3 kg
(12 lbs)
+0.26 kg/m
(0.57 lbs/39.3“)
+3.26 kg/m
(7.19 lbs/39.3“)
RF 3300
rod version
3.6 kg
(8.0 lbs)
4.6 kg
(10 lbs)
4.9 kg
(11 lbs)
+3.0 kg/m
(6.61 lbs/39.3“)
+3.26 kg/m
(7.19 lbs/39.3“)
RF 3300
rope version
4.8 kg
(11 lbs)
5.8 kg
(13 lbs)
6.1 kg
(13 lbs)
+0.26 kg/m
(0.57 lbs/39.3“)
+3.26 kg/m
(7.19 lbs/39.3“)
Total weight = Basic weight + active probe length L1 + inactive length L2
All weights with 1 1/4" NPT process connection and without anges
* Rode version with shortest length L1=100mm (3.9"), rope version without rope
**Refer to dimension drawings on page 6-8
Technical data - Mechanical Data
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Technical data - Operating conditions
Max. load with rod version
All ratings for 40°C (104°F)
Operating conditions
Ambient temp. (housing) -40°C.. +70°C (-40 .. +158°F) Standard housing. Plastics housing without Ex approvals
-20°C.. +70°C (-4 .. +158°F) Plastics housing with Ex approvals
-40°C.. +60°C (-40 .. +140°F) de- and d-housing
Process temperature RF 3100 / 3200: -40°C.. +240°C (-40 .. +464°F)
RF 3300: -40°C.. +500°C (-40 .. +932°F), versions with Ex-approvals: +445°C (+833°F)
.
For versions with Ex-approvals: see remarks on page 42.
Ventilation Ventilation is not required
Max. range / max
sensitivity
3 .. 100pF / 0.5pF
3 .. 400pF / 2pF
Spark protection Robust build in protection against static discharge of the bulk material.
Features of bulk material Min. DK depending on selected probe length L1 and probe diameter.
See tables on page 25 and 32.
Max. mechanical load
RF 3100 Rod version: A: 125 Nm B: 20 Nm
Rope version: 4 kN tensile load
RF 3200 Rod version: A: 525 Nm B: 90 Nm
Rope version: 40 kN tensile load
RF 3300 Rod version: A: 525 Nm B: 20 Nm
Rope version: 10 kN tensile load
Max. process pressure
The max. process pressure may be reduced with use of anges. Observe ange standards for
pressure rating and pressure derating with higher temperature.
For versions with Ex-approvals: Further see remarks on page 41.
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Vibration 1.5 (m/s2)2/Hz according to EN 60068-2-64
Relative Humidity 0-100%, suitable for outdoor use
Altitude max. 2.000m (6.562ft)
Expected product lifetime Following parameters have a negative inuence on the expected product lifetime:
High ambient- and process temperature, corrosive environment, high vibration, high ow rate of
abrassive bulk material passing the sensor element.
Transport and Storage
Transport Observe the instructions as stated on the transport packaging, otherwise the products may get
damaged.
Transport temperature: -40 .. +80 °C (-40 .. +176 °F)
Transport humidity: 20 .. 85 %
Transport incoming inspections must be caried out to check for possible transport damage.
Storage Products must be stored at a dry and clean place. They must be protected from inuence of corrosive
environment, vibration and exposure to direct sunlight.
Storage temperature: -40 .. +80 °C (-40 .. +176 °F)
Storage humidity: 20 .. 85 %
Technical data - Operating conditions
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Approvals
General Purpose *
(Ordinary Locations)
CE
FM / FMc
TR-CU
EN 61010-1
Hazardous
Locations *
ATEX Dust explosion
Gas explosion
Protection by enclosure
Flameproof
Flameproof / increased safety
II 1/2D Ex ia/tb IIIC T! Da/Db
II 2G Ex d ia IIC T! Gb
II 2G Ex de ia IIC T! Gb
IEC-Ex Dust explosion
Gas explosion
Protection by enclosure
Flameproof
Flameproof / increased safety
Ex ia/tb IIIC T! Da/Db
Ex d ia IIC T! Gb
Ex de ia IIC T! Gb
FM / FMc Dust explosion
Gas explosion
Protection by enclosure
Flameproof
DIP-IS Cl. II, III Div.1 Gr. E,F,G
XP-IS Cl. I Div.1 Gr. B,C,D
Cl. I Zone 1 Gr. IIB+H2
TR-CU Dust explosion
Gas explosion
Protection by enclosure
Flameproof
Flameproof / increased safety
Ex ia/tb IIIC T! Da/Db X
Ex d ia IIC T! Gb X
Ex de ia IIC T! Gb X
Detailed allocation of types and electronic modules to approvals: see selection list.
EMC EN 61326 -A1
Hygiene * EHEDG (Type ED)
Food grade material According to directive 1935/2004/EC
Pressure Equipment
Directive
(2014/68/EU)
The units are not subject to this directive, because they are classied as „pressure-keeping equipment“ and
do not have a pressurized housing (see Art.1, clause 2.1.4).
The units are designed and manufactured in accordance to the Pressure Equipment Directive.
The unit is NOT intended for use as a “equipment part with safety function (Art.1, clause 2.1.3).
If the units should be used as „equipment part with safety function, please contact the manufacturer.
* depending on selected version in the selection list.
Approvals / Options
Options
Various options are available, see pricelist for more details:
Remote version • Probe and electronic housing separated (cable length up to 20m (65ft))
Electronics • Preselected sensitivity (factory setting of switching sensitivity )
Probes • Coating rod version
• Coating rope version (rope)
• Extension kits (rigid or exible rod extension, rope extension)
Mounting • Sliding sleeve (exible height adjustment of the probe)
• EHEDG approval (Type ED)
• Mounting sets: Screws, washers, sealings for xing the unit on a ange.
Housing • Housing material plastics PA6
• Weather protection cover (PE, weathering and temperature stable)
• Cable entry (metric or NPT with different size)
• Signal lamp (indiation of signal output state from outside)
• Plugs (valve connector, M12 plug, Harting)
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General Safety Instructions
Process pressure Improper installation may result in loss of process pressure.
Seal the process thread with Teon tape in case of process pressure
A plastic sealing must be used to tighten the ange.
Fastening of the
threaded process
connection
Mounting torque for the thread may not exceed 80Nm. Use a tting open-end wrench. Do not fasten by
turning the housing.
Sliding sleeve: Tighten both straining screws M8 with 20 Nm to obtain resistance against pressure.
Precaution for later
dismounting/ Service
Grease the screws of the lid if corrosive atmosphere is present (e.g. close to sea)
Direction of the cable
glands
When the unit is mounted from the side, ensure, that the cable glands faces downwards and are closed
to avoid water penetration into the housing. The housing can be rotated against the process connection
after mounting.
Chemical resistance
against the medium
Materials of construction are chosen based on their chemical compatibility (or inertness) for general
purposes. For exposure to specic environments, check with chemical compatibility charts before
installing.
Temperature range The range of the ambient and process temperature of the device must be observed.
Mechanical load The rated values must not be exceeded.
EHEDG / Food grade
material
The materials are available for the use under normal and predictable applications (according to
directive 1935/2004 Art.3). Other conditions can inuence the safety.
Mounting
Additional Safety Instructions for Hazardous Locations
Installation regulations For devices to use in hazardous locations the respectively valid installation regulations must be
observed.
Sparks The installation has to be done in a way mechanical friction or impact can not cause sparks between
the aluminium enclosure and steel.
Weather protection
cover
The weather protection cover is approved for Zone 2, 22 and Div.2
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metal-metal
sealing
welding with
container wall
Flush welding
socket
Dimension of ush welding socket (for optional on site manufacturing):
Surfaces in contact with
process Ra <=0.8um
Section A Section B
Dimensions in mm
* suggested values
(in brackets values to be
adhered bindingly)
Metal-metal sealing:
• The support must be plane and without any gap. No teon tape (or similar) is allowed to be in between.
• Fixing torque 100Nm
The quality of the welding with the container wall must be according to the respective regulations (e.g. gaps, transitions, surface
nish).
Mounting
EHEDG Approval
Total length L + 9mm (0.35")
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Mounting
Mounting: Rod version
CORRECT
Horizontal mounting CORRECT
Oblique mounting
Helps remaining material to fall off
CORRECT
Long socket.
Use of inactive
length.
CORRECT
Extensive material build
up. Use of inactive
length.
WRONG
Active probe inside
socket. WRONG
Active probe inside
material build up.
Observe distance to
active probe
Active
probe
Active
probe
Active
probe
Active
probe
WRONG:
Active probe inside intersection between
cylindric and conical part of the silo
(material may stay when silo is empty)
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Mounting
Observe min. distance between two sensors, to metal
silo wall and to protective angle.
Grounding reference
with non metal silos
The inner or outer PE terminal must be connected to reach a grounding reference.
Further mounting
requirements
• Observe distance to material ow (lling).
• Protective angle recommended depending on mechanical load and abrasion of the material.
Switching point With proper calibration the signal output switches when the active probe is covered by material.
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Mounting
Mounting: Rope version
Observe distance to
active probe CORRECT
Long socket.
Use of inactive length.
CORRECT
Short socket.
Observe min. distance between two sensors and to
metal silo wall.
Active probe
Active probe
WRONG
Active probe
inside socket.
WRONG:
Active probe inside
intersection between
cylindric and conical part of
the silo (material may stay
when silo is empty)
Grounding reference
with non metal silos
The inner or outer PE terminal must be connected to reach a grounding reference.
Further mounting
requirements
• Observe distance to material ow (lling).
• Empty detector: Do not mount above the center of the silo outlet due to high traction force.
• Unit must be installed vertical.
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Electrical installation
Handling In the case of inexpert handling or handling malpractice the electric safety of the device cannot be
guaranteed.
Protective earthing Before any electrical installation, the terminal inside the housing must be connected to the protective
earth.
Installation regulations The local regulations or VDE 0100 (Regulations of German Electro technical Engineers) must be
observed.
WIth use of 24V supply voltage, an approved power supply with reinforced insulation to mains is
required.
Fuse Use a fuse as stated in the connection diagrams.
RCCB protection In the case of a defect, the distribution voltage must automatically be cut off by a RCCB protection
switch so as to protect the user of the device from indirect contact with dangerous electric tensions.
Power supply switch A Power-supply-disconnecting switch must be provided and marked near the device.
Wiring diagram The electrical connections have to be made according to the wiring diagram.
Supply voltage Compare the supply voltage applied with the specications given on the electronic and name plate
before switching the device on.
Cable gland / closing
element
The screwed cable gland and closing element must have following specications:
Ingress protection IP67, temperature range from -40°C to +80°C, UL or VDE certied (depending on
the country where the unit is installed), pull relief.
Make sure that the screwed cable gland safely seals the cable and that it is tight (danger of water
intrusion).
Cable glands that are not used have to be locked with a closing element.
A strain relief must be provided for the eld wiring cables, when the device is installed with the factory
provided cable glands.
Conduit system In case of using a conduit system (with NPT thread) instead of a cable gland the regulations of the
country where the unit is installed must be observed. The conduit must have a tapered thread either
NPT 1/2“ or NPT 3/4” in accordance with the unit and ANSI B 1.20.1. Not used inlets must be closed
tight with a metal closing element.
Field wiring cables • The diameter has to match to the clamping range of the used cable gland.
• The cross section has to match with the clamping range of the connection terminals and consider
the max. current.
• All eld wirings must have insulation suitable for at least 250V AC.
• The temperature rating must be at least 90°C (194°F).
• If higher immunity interferences as specied in the stated EMC standards are present (see chapter
approval), a shielded cable is required, otherwise an unshielded instrumentation cable is
satisfactory.
Connecting the terminals Make sure that max. 8mm (0.31“) of the pigtails are bared (danger of contact with live parts).
Guiding the cables in the
terminal box
Cut the eld wiring cables to appropriate length to t properly into the terminal box.
Remote housing The remote cable must be installed sepatated from power supply lines to avoid immunity
interferences The min. bending radius of 50mm must be observed.
General Safety Instructions
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RF 3000 d gi241014
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Level limit switch
Series RF 3000
Technical Information / Instruction manual
page
Electrical installation
Relay protection Provide protection for relay contacts to protect the device against spikes with inductive loads.
Protection against static
charging
The housing of the unit must be grounded in any case to avoid static charging of the unit on
applications with pneumatic conveying and non-metallic containers .
Opening the lid Before opening the lid take care, that the unit is clean and no water or dirt can enter into the housing.
Additional Safety Instructions for Hazardous Locations
External equipotential
bonding terminal
Connect with
equipotential
bonding of
the plant
Field wiring A pull relief must be provided for the eld wiring cables, when the device is installed with the factory
provided cable glands.
Field wiring terminals for
“de” housing
Fixing torque : 0,5-0,6Nm
Remove wire isolation: 9mm
Cable glands and conduit
system for ATEX /
IEC-Ex/ TR-CU
(Dust and Gas Hazardous
Locations)
Installation according to the regulations of the country, where the product is installed.
Not used entries have to be closed with blanking elements certied for this purpose.
Where available the factory provided parts must be used.
A strain relief must be provided for the eld wiring cables, when the device is installed with the factory
provided cable glands.
If other than the factory provided parts are used, following must be ensured:
The parts must have an approval adequate to the approval of the level sensor (certicate and type of
protection).
The approved temperature range must be from the min. ambient temperature of the level sensor to the
max. ambient temperature of the level sensor increased by 10 Kelvin.
The parts must be mounted according to the instructions of the supplier.
Conduit system
for FM
(Dust and Gas Hazardous
Locations)
General requirements:
In addition the regulations of the country must be observed. The used ameproof seals and blanking
elements must have an adequate type approval and a temperature range of at least –40°C (-40°F)
to +80°C (176°F). In addition they shall be suitable for the conditions and correctly installed. Where
available the provided original parts of the manufacturer must be used.
Installation of a ameproof enclosure “d” with a conduit system:
In a conduit system single electric conductors are installed in a certied pipe system. This pipe system
is in a ameproof construction as well. The ameproof enclosure “d” and the pipe system needs to be
sealed from each other by a certied ameproof seal. Conduit entries of a ameproof enclosure “d”
shall have installed the ameproof seal within 18 inches from the enclosure wall. Not used entries have
to be closed with adequate blanking elements of a certied ameproof type Cl.1 Div.1 A.
Opening the lid Units with Dust Explosion approval:
Before opening the lid take care, that no dust deposits or whirlings and no hazardous atmosphere is
present.
Units with ameproof GasExplosion approval (d-housing):
To prevent ignition of hazardous atmospheres, do not remove the lid (cover) while circuits are alive.
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