WIKA FLR Series User manual

DE
EN
Operating instructions
Betriebsanleitung
Level sensor, model FLR
Niveau-Messwertgeber, Typ FLR
Level sensor with reed switch chain technology
Model FLR

017461.02 10/2016 EN/DE
DE
EN
2Operating instructions level sensor, model FLR
Operating instructions level sensor
Model FLR Page 3 - 18
Betriebsanleitung Niveau-Messwertgeber
Typ FLR Seite 19 - 34
© 09/2016 WIKA Alexander Wiegand SE & Co. KG
All rights reserved. / Alle Rechte vorbehalten.
WIKA®and KSR®are registered trademarks in various countries.
WIKA®and KSR®sind geschützte Marken in verschiedenen Ländern.
Prior to starting any work, read the operating instructions!
Keep for later use!
Vor Beginn aller Arbeiten Betriebsanleitung lesen!
Zum späteren Gebrauch aufbewahren!

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3Operating instructions level sensor, model FLR
017461.02 10/2016 EN/DE
Contents
Declarations of conformity can be found online at www.wika.com.
Contents
1. General information 4
2. Design and function 5
3. Safety 6
4. Transport, packaging and storage 11
5. Commissioning, operation 13
6. Faults 15
7. Maintenance and cleaning 16
8. Dismounting, return and disposal 17
9. Specifications 18
Appendix 1: EU declaration of conformity 35

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4Operating instructions level sensor, model FLR
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1. General information
1. General information
■
The level sensors described in the operating instructions have been
designed and 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
ISO 9001.
■
These operating instructions contain important information on
handling the instrument. 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 instrument’s range of use.
■
The operating instructions are part of the product and must be kept
in the immediate vicinity of the instrument and readily accessible to
skilled personnel at any time. Pass the operating instructions on to
the next operator or owner of the instrument.
■
Skilled personnel must have carefully read and understood the
operating instructions prior to beginning any work.
■
The general terms and conditions contained in the sales documenta-
tion shall apply.
■
Subject to technical modifications.
■
Further information:
- Internet address: www.wika.de / www.wika.com
- Relevant data sheet: LM 20.02

EN
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≤ 30°

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5Operating instructions level sensor, model FLR
017461.02 10/2016 EN/DE
2. Design and function
2.1 Functional description
Level sensors work on the float principle with magnetic transmission.
A permanent magnet built into the float triggers, with its magnetic
field, the resistance measuring chain built into the guide tube.The entire
assembly corresponds to a 3-wire potentiometer circuit.The float 
changes its height with the level of the medium it is monitoring.The
measured resistance signal is proportional to the level.The measure-
ment voltage is very finely-stepped due to the contact separation of the
resistance measuring chain and is thus virtually continuous.
2. Design and function
Connection housing
Cable gland
Spanner flats for screwing in
Sealing
Guide tube
Float
Teflon disc
Float stop
2.2 Scope of delivery
Cross-check scope of delivery with delivery note.

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3. Safety
3.1 Explanation of symbols
DANGER!
... indicates a directly dangerous situation resulting in
serious injury or death, if not avoided.
WARNING!
... indicates a potentially dangerous situation that can result
in serious injury or death, if not avoided.
CAUTION!
... indicates a potentially dangerous situation that 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.
3.2 Intended use
Level sensors are used exclusively for monitoring the levels of liquid
media.
The scope of application is defined by the technical performance limits
and materials.
2. Design and function / 3. Safety

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7Operating instructions level sensor, model FLR
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3. Safety
■
The liquids must not have any large contamination or coarse
particulates and must not have a tendency to crystallise. Ensure that
the wetted materials of the level sensor are sufficiently resistant to
the medium being monitored. Not suitable for dispersions, abrasive
liquids, highly viscous media and colours.
■
This instrument is not permitted to be used in hazardous areas! For
these areas, level sensors with approval (e.g. in accordance with
ATEX) are required.
■
The operating conditions specified in the operating instructions must
be observed.
■
Do not operate the instrument in the direct vicinity of ferromagnetic
environments (min. distance 50 mm).
■
Do not operate the instrument in the immediate vicinity of strong
electromagnetic fields or in the immediate vicinity of equipment that
can be affected by magnetic fields (min. clearance 1 m).
■
The level sensors must not be exposed to heavy mechanical strain
(impact, bending, vibration).
■
The technical specifications contained in these operating instructions
must be observed. Improper handling or operation of the instrument
outside of its technical specifications requires the instrument to be
taken out of service immediately and inspected by an authorised
WIKA service engineer.
The instrument has been designed and built solely for the intended use
described here, and may only be used accordingly.

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8Operating instructions level sensor, model FLR
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The manufacturer shall not be liable for claims of any type based on
operation contrary to the intended use.
DANGER!
Work on vessels involves the danger of intoxication and
suffocation. No work is allowed to be carried out unless by
taking suitable personal protective measures (e.g. respirato-
ry protection apparatus, protective outfit etc.).
3.3 Improper use
Improper use is defined as any application that exceeds the technical
performance limits or is not compatible with the materials.
WARNING!
Injuries through improper use
Improper use of the instrument can lead to hazardous situa-
tions and injuries.
▶
Refrain from unauthorised modifications to the instru-
ment.
▶
Do not use the instrument within hazardous areas.
Any use beyond or different to the intended use is considered as
improper use.
Do not use this instrument in safety or emergency stop devices.
3.4 Responsibility of the operator
The instrument is used in the industrial sector. The operator is therefore
responsible for legal obligations regarding safety at work.
The safety instructions within these operating instructions, as well as the
safety, accident prevention and environmental protection regulations for
the application area must be maintained.
3. Safety

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9Operating instructions level sensor, model FLR
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To ensure safe working on the instrument, the operating company must
ensure the following:
■
The operating personnel are regularly instructed in all topics regard-
ing work safety, first aid and environmental protection and know
the operating instructions and in particular, the safety instructions
contained therein.
■
The operating personnel have read the operating instructions and
taken note of the safety instructions contained therein.
■
The intended use for the application is complied with.
■
Following testing, improper use of the instrument is excluded.
3.5 Personnel qualification
WARNING!
Risk of injury should qualification be insufficient
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.
Skilled personnel
Skilled personnel, authorised by the operator, 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 direc-
tives, are capable of carrying out the work described and independently
recognising potential hazards.
3.6 Personal protective equipment
The personal protective equipment is designed to protect the skilled
personnel from hazards that could impair their safety or health during
work.When carrying out the various tasks on and with the instrument,
the skilled personnel must wear personal protective equipment.
3. Safety

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3. Safety
Follow the instructions displayed in the work area regarding
personal protective equipment!
The requisite personal protective equipment must be provided by the
operating company.
3.7 Labelling, safety marks
Product label
Model designation / model
Instrument code
Circuit diagram with colour coding per IEC 757
Serial number
Article number
Measuring point number
Ingress protection per EN/IEC 60529
Symbol of protection class per EN 61140
Switching power
Before mounting and commissioning the instrument, ensure you read the
operating instructions!
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4. Transport, packaging and storage
4.1 Transport
Check the level sensor for any damage that may have been caused by
transport.
Obvious damage must be reported immediately.
CAUTION!
With improper transport, a high level of damage to property
can occur.
▶
Observe the symbols on the packaging
▶
Handle packed goods with care
4.2 Packaging and storage
Do not remove packaging until just before commissioning.
Keep the packaging as it will provide optimum protection during trans-
port (e.g. change in installation site, sending for repair).
5. Commissioning, operation
■
Observe all instructions given on the shipment packaging for remov-
ing the transportation safety devices.
■
Remove the level sensor carefully from the packaging!
■
When unpacking, check all components for any external damage.
5.1 Functional check
Prior to installation, a functional test of the level sensor can be carried
out with a resistance measuring instrument and manual movement of
the float.
4. Transport ... / 5. Commissioning, operation

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5. Commissioning, operation
The following table describes the measurements and the expected
measured values for the movement of the float, starting from the float
stop in the direction of the tank opening.
Resistance measurement
of the wire colours
Measured value
BK ― BN (R1) Resistance value rises proportionally with the
height of the float.
BU ― BN (R2) Resistance value drops in inverse proportion
to the height of the float.
BK ― BU (Ri) Resistance value remains constant, irrespec-
tive of the position of the float.
WARNING!
Ensure that the functional check does not start any
unintended processes.
5.2 Mounting preparation
■
Ensure that the sealing faces of the vessel or level sensor are clean
and do not show any mechanical damage.
5.3 Mounting
■
Observe the torque values of screws specified in pipefitting work.
■
In the selection of the mounting material (sealings, screws, washers
and nuts), take the process conditions into account. The suitability
of the sealing must be specified with regard to the medium and its
vapours. In addition, ensure it has corresponding corrosion resist-
ance.
■
The level sensor is mounted to the vessel from the outside
■
The guide tube should not be inclined more than a maximum of
30° to the vertical.
■
Mount the level sensor correctly for the design of the process
connection.
■
If the opening of the process connection is too small for the float, the

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≤ 30°
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13Operating instructions level sensor, model FLR
017461.02 10/2016 EN/DE
float must be removed before
mounting.
- Before removal, mark the
position of the float stop 
with a waterproof pen
- Mark the mounting position of
the float (e.g.“Up”)
- After the level sensor has
been mounted, the float
should be re-attached within
the inside of the tank (pay
attention to the mounting
position!).
- Secure the float stop again
at the marked point.
5.4 Electrical connection
■
The electrical connection must only be made by qualified skilled
personnel.
■
Wire the level sensor in accordance with the connection diagram of
the electrical output (see product label).The connection terminals
are appropriately marked.
Electrical output Connection diagram
The entire assembly
corresponds to a 3-wire
potentiometer circuit
BU/GY
BN
BK
5. Commissioning, operation

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Electrical output Connection diagram
Head-mounted transmitter
with 4 ... 20 mA R
I
A
4 ... 20mA
+
–
DC 12 ... 30V
■
Seal the cable bushing at the connection housing .
WARNING!
Malfunctions through voltage spikes due to running cables
together with mains connection leads or due to large cable
lengths.
This can lead to a malfunction in the plant and thus lead to
injury to personnel or damage to equipment.
▶
Use shielded connection leads
▶
Ground connection leads at one end
Always observe the mounting and operating instructions of accessories
when commissioning them.
5. Commissioning, operation

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6. Faults
6. Faults
The following table contains the most frequent causes of
faults and the necessary countermeasures.
Faults Causes Measures
Level sensor
cannot be
mounted at the
planned place on
the vessel
Process connection of the
level sensor does not match
to the process connection of
the vessel.
Modification of the vessel
Return to the factory
Process connection at the
vessel defective
Rework the thread or
replace the screwed
coupling
Mounting thread at the level
sensor defective
Return to the factory
No signal,
non-linear or
undefined signals
Electrical connection
incorrect
See chapter 5.4 “Electrical
connection”. Check the
assignment with the aid of
the connection diagram.
Measuring chain defective Return to the factory
Head-mounted transmitter
defective
Head-mounted transmitter
adjusted incorrectly
CAUTION!
Physical injuries and damage to property and the
environment
If faults cannot be eliminated by means of the listed
measures, the instrument must be taken out of operation
immediately.
▶
Ensure that there is no longer any pressure present and
protect against being put into operation accidentally.
▶
Contact the manufacturer.
▶
If a return is needed, please follow the instructions given
in chapter 8.2 “Return”.

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7. Maintenance and cleaning
7.1 Maintenance
The level sensors work maintenance-free in normal operation.They
must be subjected to visual inspection within the context of regular
maintenance, however, and included in the vessel pressure test.
DANGER!
Work on containers involves the danger of intoxication and
suffocation. No work is allowed to be carried out unless by
taking suitable personal protective measures (e.g. respirato-
ry protection apparatus, protective outfit etc.).
Repairs must only be carried out by the manufacturer.
Perfect functioning of the level sensors can only be guaran-
teed when original accessories and spare parts are used.
7.2 Cleaning
CAUTION!
Physical injuries and damage to property and the
environment
Improper cleaning may lead to physical injuries and damage
to property and the environment. Residual media in the
dismounted instrument can result in a risk to persons, the
environment and equipment.
▶
Rinse or clean the removed instrument.
▶
Sufficient precautionary measures must be taken.
1. Prior to cleaning, properly disconnect the instrument from the process
and the power supply.
2. Clean the instrument carefully with a moist cloth.
3. Electrical connections must not come into contact with moisture!
7. Maintenance and cleaning

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7. ... / 8. Dismounting, return and disposal
CAUTION!
Damage to property
Improper cleaning may lead to damage to the instrument!
▶
Do not use any aggressive cleaning agents.
▶
Do not use any pointed and hard objects for cleaning.
8. Dismounting, return and disposal
WARNING!
Physical injuries and damage to property and the
environment through residual media
Residual media in the dismounted instrument can result in a
risk to persons, the environment and equipment.
▶
Wash or clean the dismounted instrument, in order to
protect persons and the environment from exposure to
residual media.
8.1 Dismounting
Only disconnect the measuring instrument once the system has been
depressurised and the power disconnected!
8.2 Return
Wash or clean the dismounted level sensor before returning it, in order
to protect personnel and the environment from exposure to residual
media.
Information on returns can be found under the heading
“Service” on our local website.

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8.3 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.
9. Specifications
Operating limits
■
Operating temperature:T = -80 ... +200 °C
■
Operating pressure: p = -1 ... 80 bar
Models FLR-SA, FLR-SE,
FLR-SF, FLR-PA, FLR-PE,
FLR-PF, FLR-HA, FLR-HE,
FLR-MA, FLR-ME, FLR-MF,
FLR-HA3
Models FLR-SB,
FLR-PB, FLR-HB,
FLR-MB, FLR-HB3
Permissible
power supply
≤ AC 50 V; ≤ DC 75 V see the data sheet
of the head-mounted
transmitter used
Resolution 2.7 mm, 5.5 mm, 7.5 mm, 9 mm (depending on version)
EU declaration
of conformity
not required see Appendix 1
For further specifications see data sheet LM 20.02
8. Dismounting ... / 9. Specifications

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19Betriebsanleitung Niveau-Messwertgeber, Typ FLR
017461.02 10/2016 EN/DE
Inhalt
Konformitätserklärungen finden Sie online unter www.wika.de.
Inhalt
1. Allgemeines 20
2. Aufbau und Funktion 21
3. Sicherheit 22
4. Transport, Verpackung und Lagerung 27
5. Inbetriebnahme, Betrieb 29
6. Störungen 31
7. Wartung und Reinigung 32
8. Demontage, Rücksendung und Entsorgung 33
9. Technische Daten 34
Anlage 1: EU-Konformitätserklärung 35

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20 Betriebsanleitung Niveau-Messwertgeber, Typ FLR
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1. Allgemeines
1. Allgemeines
■
Die in der Betriebsanleitung beschriebenen Niveau-Messwertgeber
werden nach dem aktuellen Stand der Technik konstruiert und gefer-
tigt. Alle Komponenten unterliegen während der Fertigung strengen
Qualitäts- und Umweltkriterien. Unsere Managementsysteme sind
nach ISO 9001 zertifiziert.
■
Diese Betriebsanleitung gibt wichtige Hinweise zum Umgang mit
dem Gerät.Voraussetzung für sicheres Arbeiten ist die Einhaltung
aller angegebenen Sicherheitshinweise und Handlungsanweisun-
gen.
■
Die für den Einsatzbereich des Gerätes geltenden örtlichen Unfall-
verhütungsvorschriften und allgemeinen Sicherheitsbestimmungen
einhalten.
■
Die Betriebsanleitung ist Produktbestandteil und muss in unmittel-
barer Nähe des Gerätes für das Fachpersonal jederzeit zugänglich
aufbewahrt werden. Betriebsanleitung an nachfolgende Benutzer
oder Besitzer des Gerätes weitergeben.
■
Das Fachpersonal muss die Betriebsanleitung vor Beginn aller Arbei-
ten sorgfältig durchgelesen und verstanden haben.
■
Es gelten die allgemeinen Geschäftsbedingungen in den Verkaufs-
unterlagen.
■
Technische Änderungen vorbehalten.
■
Weitere Informationen:
- Internet-Adresse: www.wika.de / www.wika.com
- Zugehöriges Datenblatt: LM 20.02