WIKA FLM-CA User manual

Operating instructions
Betriebsanleitung
EN
DE
Magnetostrictive level transmitter, models FLM-CA, FLM-CM
Magnetostriktiv-Füllstandstransmitter, Typen FLM-CA, FLM-CM
Mounting flange, spherical float from
stainless steel, model FLM-CA
Mounting thread, cylinder float from
stainless steel, model FLM-CM

EN
DE
2
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Operating instructions magnetostrictive level transmitter, model FLM-CA, FLM-CM
Operating instructions models FLM-CA, FLM-CM Page
3 - 26
Betriebsanleitung Typen FLM-CA, FLM-CM Seite
27 - 50
© 09/2019 WIKA Alexander Wiegand SE & Co. KG
All rights reserved. / Alle Rechte vorbehalten.
WIKA®is a registered trademark in various countries.
WIKA®ist eine geschützte Marke 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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Operating instructions magnetostrictive level transmitter, models FLM-CA, FLM-CM 3
Contents
Contents
1. General information 4
2. Design and function 4
3. Safety 7
4. Transport, packaging and storage 9
5. Commissioning, operation 10
6. Faults 20
7. Maintenance and cleaning 21
8. Dismounting, return and disposal 23
9. Specifications 24

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Operating instructions magnetostrictive level transmitter, models FLM-CA, FLM-CM4
1. General information
■
The magnetostrictive level transmitters 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 documentation shall apply.
■
Subject to technical modifications.
■
Further information:
- Internet address: www.wika.de / www.wika.com
- Relevant data sheet: LM 20.04 (FLM-CA)
LM 20.05 (FLM-CM)
2. Design and function
2.1 Description
The models FLM-CA and FLM-CM high-accuracy level transmitters are used for the
continuous measurement of the level of liquid media in vessels. The measurement
procedure used exploits the physical effect of magnetostriction and is largely independent
of the temperature. It is used, especially, where very precise level measurements are
required, such as in the chemical industry.
In these operating instructions, the FLM is described with cable connection on the side of
the probe head. As cable connection, an M12 cable gland (also with M16 adapter), an M12
connector or an M20 or ½ NPT female thread are possible. As a further variant, there is an
FLM with an M12 connector on the probe head cover.
1. General information / 2. Design and function

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Operating instructions magnetostrictive level transmitter, models FLM-CA, FLM-CM 5
The FLM-Cx emits a 4 … 20 mA output signal, which is configured via buttons within the
probe head, or a digital output signal as HART®protocol.
Probe lengths of 100 mm to 6 m, as “Flex version” up to 10 m, and also various
temperature and pressure ranges are possible.
Available versions:
■
With screw-in body, welded or for step-free positioning
■
With flange process connection
■
For mounting on a bypass with magnetic float
■
With 90° angled probe head
■
With 6 mm guide tube
■
With 6 mm guide tube and short cable bushing
2.2 Construction and principle of operation
The construction of the model FLM-Cx level transmitter is illustrated in the version with
screw-in body. In the probe head of the level transmitter are located the connection
terminals and the adjustment buttons protected by the cover .The electrical connection
is made via an M16 x 1.5 cable gland or M12 plug connection on the top of the probe
head and the ground connection at the bottom of the probe head (see chapter 5.1
“Mounting” and 5.3 “Adjustment”).
On the guide tube , for highly-adjustable mounting in the vessel, there is a screw-in
body (compression fitting) or, for fixed mounting, a flange (not shown).The float is
used for the continuous measurement of the product filling height or interface layer and is
held on the guide tube by an adjusting collar .
The “BLM for bypass fitting” version is delivered without process connection and float.







2. Design and function

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Operating instructions magnetostrictive level transmitter, models FLM-CA, FLM-CM6
The measurement procedure shown in the following figure exploits the physical effect of
magnetostriction and is largely independent of the temperature. In the guide tube, a wire 
from magnetostrictive material is stretched. Via the sensor electronics, current pulses 
are sent through the wire, which generate a circular magnetic field . A magnet , which
is built into the float, acts as the level pick-up. Its magnetic field magnetises the wire axially.
Through the interference of the two magnetic fields, in the area of the float magnet, a
torsion wave is generated, which runs in both directions along the wire. One wave runs
directly to the probe head, the other is reflected off the lower end of the guide tube.The
time between the sending of the current pulse and the arrival of the wave at the probe head
is measured. From the time elapsed, the float position is determined.
2.3 Scope of delivery
Cross-check scope of delivery with delivery note.






2. Design and function

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Operating instructions magnetostrictive level transmitter, models FLM-CA, FLM-CM 7
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 property or the environment, if not avoided.
Information
... points out useful tips, recommendations and information for efficient and
trouble-free operation.
3.2 Intended use
Magnetostrictive level transmitters are used exclusively for the continuous measurement of
the level of liquid media in vessels.
This instrument is not permitted to be used in hazardous areas!
The instrument has been designed and built solely for the intended use described here,
and may only be used accordingly.
The manufacturer shall not be liable for claims of any type based on operation contrary to
the intended use.
3.3 Improper use
Improper use is defined as any application that exceeds the technical performance limits.
WARNING!
Injuries through improper use
Improper use of the instrument can lead to hazardous situations and injuries.
▶
Refrain from unauthorised modifications to the instrument.
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. Safety

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Operating instructions magnetostrictive level transmitter, models FLM-CA, FLM-CM8
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.
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 know the operating instructions and, in
particular, the safety instructions contained therein.
■
that the instrument is suitable for the particular application in accordance with its
intended use.
3.5 Personnel qualification
WARNING!
Risk of injury should qualification be insufficient
Improper handling can result in considerable injury and damage to property.
▶
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
directives, are capable of carrying out the work described and independently recognising
potential hazards.
Special operating conditions require further appropriate knowledge, e.g. of aggressive
media.
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.
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. Safety

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Operating instructions magnetostrictive level transmitter, models FLM-CA, FLM-CM 9
3.7 Labelling, safety marks
Product label
Model
Model code
Serial number
Article number
Tag no.
Electrical data, IP ingress protection
Before mounting and commissioning the instrument, ensure you read the
operating instructions!
4. Transport, packaging and storage
4.1 Transport
Check the instrument for any damage that may have been caused by transport.
Obvious damage must be reported immediately.
CAUTION!
Damage through improper transport
With improper transport, a high level of damage to property can occur.
▶
When unloading packed goods upon delivery as well as during internal
transport, proceed carefully and observe the symbols on the packaging.
▶
With internal transport, observe the instructions in chapter 4.2 “Packaging
and storage”.
4.2 Packaging and storage
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).
Level sensor FLM
Type:
Ser. No.:
Art. No.:
Tag. No.:
IP68 max. DC 15 ... 30 V
4 ... 20 mA
WIKA Alexander Wiegand SE & Co. KG
Alexander-Wiegand-Strasse 30
63911 Klingenberg
WIKA Alexander Wiegand SE & Co. KG
Alexander-Wiegand-Strasse 30
63911 Klingenberg
Level Sensor ???????
T
ype: ???-????????????????
????????????????
4-20 mA
TÜV 18 ATEX 225120 X
I
I 1/2 G Ex ia IIC T6…T3 Ga/Gb
II 1 D Ex ia IIIC T160°C Da
0637
Ui=<30V; Pi=<1W; li=<200mA; Ci=<10nF; Li=<20µH
Bj.:????






3. Safety / 4. Transport, packaging and storage

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Operating instructions magnetostrictive level transmitter, models FLM-CA, FLM-CM10
5. Commissioning, operation
DANGER!
Risk of injury due to improper use
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. breathing apparatus, protective clothing etc.).
▶
Work on the instrument must only be carried out by trained skilled
personnel.
5.1 Mounting
■
During mounting, ensure that the guide tube is not bent and that the float is not
subjected to shock loads.
■
The installation of the level transmitter in areas with strong external magnetic fields is
not permitted, since this will impede the correct measured value determination.
■
The level transmitter can also be installed in the vessel from below. If the vessel is also
pressurised, then the maximum length of the level transmitter is 2 m.
Guide tube length Guide tube length
Insertion length
Guide tube
Screw-in body Flange Mounting on bypass
Probe head Probe head
Neck tube
Flange
Screw-in
body
112 112 116
Float Float
Adjusting
collar
Adjusting
collar
Guide tube
88
5. Commissioning, operation

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Operating instructions magnetostrictive level transmitter, models FLM-CA, FLM-CM 11
■
If, during mounting, the float is removed, it must be slid back onto the guide tube with
the marking “TOP” in the direction of the probe head, so that correct measurement can
be made.
5.1.1 “Screw-in body” version
The dismounting of the float is then only required if the float cannot pass
through the mounting hole in the vessel. Otherwise, only mounting steps 3, 6
and, if necessary, 7 must be carried out.
Inserting the level transmitter into the vessel:
1. Loosen both threaded pins, remove the adjusting collar and remove the float from
the guide tube .
2. If necessary, slide the screw-in body onto the guide tube.
3. Insert the level transmitter into the vessel, apply suitable sealing material to, screw in
and tighten the mounting thread .
4. Slide the float back onto the guide tube .
The float must be slid back onto the guide tube with the marking “TOP” in the
direction of the probe head, so that correct measurement can be made.
5. Re-affix the adjusting collar , position and secure the threaded pins over the groove.
6. Position the process connection to its height and tighten the union nut finger-tight by
hand.





5. Commissioning, operation

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Operating instructions magnetostrictive level transmitter, models FLM-CA, FLM-CM12
7. Secure the union nut with a spanner through a 1 ¼ turn (see following figure).
5.1.2 “Flange” version
The guide tube is firmly welded to the flange, so the insertion length cannot be changed.
Secure the flange and the flange sealing with the flange screws and nuts.The screws, nuts
and seals are the responsibility of the operator and should be chosen dependent upon the
measuring medium.The fixing equipment and sealings must fulfil the requirements of the
EN 1092-1, EN 1514 and EN 1515 standards.
Should the float be unable to pass through the mounting hole, see mounting instructions,
chapter 5.1.1 ““Screw-in body” version”.
5.1.3 “Mounting on bypass” version
The level transmitter is mounted on the outside of the bypass tube with suitable mounting
material (non-magnetic) (see following figure).
To ensure a reliable measurement, the guide tube must be mounted free of
tension, without external deformations.
▶
The distance between guide tube and bypass tube must be as slow as possible.
▶
Only floats approved by us can be used.
Securing the compression fitting

5. Commissioning, operation

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Operating instructions magnetostrictive level transmitter, models FLM-CA, FLM-CM 13
Mounting with bypass
Guide tube length
Measuring range
min. magnet
position
min. magnet
position
Bypass float
Guide tube,
mounted free
of tension (not
deformed)
Bypass tube
Magnet position
Probe fixing
(un-magnetic)
Spacer
Section A-A
BLM for bypass
Distance from guide tube to centre of float:
max. distance depending on bypass float
5. Commissioning, operation

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Operating instructions magnetostrictive level transmitter, models FLM-CA, FLM-CM14
5.2 Electrical connection
5.2.1 Connection diagram
▶
Connection of the cable, see chapter 5.2.3 “Wiring with cable gland” and 5.2.4 “Wiring
with M12 connector”
Voltage source Umax = DC 30 V
Minimum supply voltage Umin = 8 V
Overall resistance (incl. wiring resistance and load): ΣR = (U - Umin) / 0.0215 A
5.2.2 Cable length
The maximum cable length is dependent upon the overall resistance, which is composed
of the wiring resistance and the load of connected instruments (see chapter 5.2.1
“Connection diagram”).
The cable (length and cross-section) must be selected such that, in the event of the
highest current supply (21.5 mA), the voltage does not drop below the probe-specific
minimum supply voltage (8 V).
Maximum overall resistance with different supply voltages and also cable resistances at
different cross-sections:
Supply
voltage in V
Max. overall
resistance in Ω
Cable cross-
section in mm²
Cable resistance per m
of copper cable in Ω/m
12 (-5 %) 158 0.5 0.0356
1.0 0.0178
1.5 0.0119
24 (-5 %) 688 0.5 0.0356
1.0 0.0178
1.5 0.0119
Voltage source
Load
Wiring resistance
5. Commissioning, operation

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Operating instructions magnetostrictive level transmitter, models FLM-CA, FLM-CM 15
The maximum cable length is calculated as follows:
L = Cable length in m
U = Supply voltage V (with negative tolerance value -5 %)
Umin = Minimum supply voltage V = 8 V
Imax = highest current supply A = 0.0215 A
RB= Load
RQ = Cable resistance of copper cable (per m) in Ω/m with cable cross-section Q in mm²
Example:
Supply voltage: 12 V (±5 %)
Supply voltage U = 11.4 V (12 V - 5 %)
Minimum supply voltage Umin = 8 V
Highest current supply Imax = 0.0215 A
Load RB = 86.8 Ω
Cable resisatance RQ = 0.0356 Ω/m with cable cross-section Q = 0.5 mm²
A cable with a forward and return line (2-wire) can therefore be a maximum of 1,000 m
long.
5. Commissioning, operation

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Operating instructions magnetostrictive level transmitter, models FLM-CA, FLM-CM16
5.2.3 Wiring with cable gland
The wiring should only be carried out in the unpowered state.
Carry out the wiring of the level transmitter as follows:
1. Unscrew the probe head cover using an open-ended spanner.
2. Loosen the union nut of the cable gland .
3. Thread the 2-wire cable into the union nut and tighten (outer diameter: 5 … 10 mm).
4. Remove the screw terminal .
5. Connect the 2-wire cable to the poles marked with (+) and (–) on the screw terminal .
6. Re-affix the screw terminal .The cable must not have any tension!
7. If required, set reference points (see chapter 5.3.1 “Measuring span on the level
transmitter”).
8. Screw the probe head cover back down.
Removable screw terminal









5. Commissioning, operation

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Operating instructions magnetostrictive level transmitter, models FLM-CA, FLM-CM 17
The ground connection on the underside of the probe head can be used for grounding or
equipotential bonding.
CAUTION!
Damage due to incorrect mounting
The probe head and the electronics can be damaged through ingress of water.
▶
Protect the probe head against water ingress. A safe sealing of the cable
entry is guaranteed with an outer cable diameter of 5 ... 10 mm.
▶
Screw the cable gland and probe head cover tight.
5.2.4 Wiring with M12 connector
The wiring should only be carried out in the unpowered state.
If not yet connected, plug the coupling of the connection cable onto the M12 connector
of the probe head. First turn the M12 connector till it is hand-tight and then secure the nut
with a 180° turn using an open-ended spanner.The tightening torque should be between
100 ... 150 cNm.
Connect the cable coming from the evaluation unit with the connection cable, e.g. using an
installation sleeve in the following assignment:
Signal Colour coding Assignment
Voltage + Brown Pin 1
Not in use White Pin 2
Voltage - Blue Pin 3
Not in use Black Pin 4
Pin assignment of the coupling of the WIKA connection cable
Characteristic for connection cable between FLM-Cx and associated equipment:
2-wire, non-shielded cable
The grounding or the equipotential bonding must be carried out by the installer in
accordance with the applicable national installation regulations. The ground connection of
the probe head can be used for the grounding or the equipotential bonding. Please also
observe the general installation regulations.
Pin 1Pin 2
Pin 3
Pin 4
5. Commissioning, operation

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Operating instructions magnetostrictive level transmitter, models FLM-CA, FLM-CM18
5.3 Adjustment
For variants with HART®protocol, the settings described in the following can also be made
conveniently remotely without having to open the probe head.
5.3.1 Measuring span on the level transmitter
For the adjustment of the 4 mA and 20 mA points on the level transmitter, there are two
buttons (and ) and a light-emitting diode (LED) in the connection area of the probe
head.
Maximum measuring span (factory-set):
4 mA at the probe foot and 20 mA at the probe head
The measuring span can be set individually for adjustment to the respective vessel.
Minimum distance of 10 mm must not be breached! If this minimum distance is breached,
the display direction of the level transmitter reverses automatically (empty quantity
measurement).
Through the adjustment, the specification of the measured value can also be inverted, e.g.
the level transmitter can be set with a maximum measuring span with 4 mA at the probe
head and 20 mA at the probe foot.
1. Unscrew the probe head cover using an open-ended spanner.
2. Hold down the 4 mA button or 20 mA button for a period of at least 3 seconds. The
green LED starts to blink.
Adjustment of the measuring span




5. Commissioning, operation

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Operating instructions magnetostrictive level transmitter, models FLM-CA, FLM-CM 19
3. The level transmitter enters adjustment mode. The current supply of the level transmitter
is 12 mA. Without pressing the button again, the level transmitter remains in adjustment
mode for 20 seconds before it switches back to measuring mode without changing the
adjustment. In adjustment mode, the 4 mA and the 20 mA reference point or both can
now be changed in any order.
4. Define a reference point: Move float to the desired reference point and
■
press the “4 mA” button briefly (0.1 … 2 seconds), in order to define a current
supply of 4 mA at this position.
■
press the “20 mA” button briefly (0.1 … 2 seconds), in order to define a current
supply of 20 mA at this position.
After pressing the “4 mA” button, the LED goes out for 5 seconds, after
pressing the “20 mA” button, the LED lights up for 5 seconds continuously.
Subsequently, the sensor remains for a further 15 seconds in adjustment
mode before saving the change and reverting to measuring mode.
The adjustment of the measuring range is only saved when the level
transmitter automatically changes from adjustment mode to measuring mode
and the LED goes out.The adjustment is retained even if the level transmitter
is subsequently disconnected from the power supply.
In order to be able to make the setting “dry” for bypass sensors, the manufacturer of the
bypass requires a magnetic system with spacer.The adjustment can then also be carried
out on the dismounted sensor.
5.3.2 Current supply in error mode
If the level transmitter cannot detect a meaningful float position (i.e. a correct level) due to a
fault, it switches to an error mode after a short time.The signalisation in error mode conforms
to NAMUR NE43 and is factory-set to 21.5 mA - it can, however, be set to 3.6 mA.
To adjust the current supply in the error mode, see figure page 18.
1. Unscrew the probe head cover using an open-ended spanner.
2. Hold down both the “4 mA” button and the “20 mA” button simultaneously for a
period of at least 3 seconds.
The green LED “Cal/Err” blinks rapidly. The current supply of the level transmitter
is 16 mA. After 5 seconds the LED no longer blinks and displays the set error current
supply for 2.5 seconds. If the LED is permanently lit, IError = 21.5 mA, if the LED goes
out, IError = 3.6 mA.Without pressing the button again, the level transmitter remains in
error mode for another 2.5 seconds before it would switch back to measuring mode
without changing the setting.
5. Commissioning, operation

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Operating instructions magnetostrictive level transmitter, models FLM-CA, FLM-CM20
3. To set a current supply
■
of 3.6 mA, during the dwell time (10 seconds) in error mode, press the “4 mA” button
briefly (0.1 ... 2 seconds).
■
of 21.5 mA, during the dwell time (10 seconds) in error mode, press the “20 mA”
button briefly (0.1 ... 2 seconds).
The adjustment of the measuring range is only saved when the level
transmitter automatically changes from adjustment mode to measuring mode
and the LED goes out.The adjustment is retained even if the level transmitter
is subsequently disconnected from the power supply.
4. Screw the probe head cover back down.
If the level transmitter detects, during operation, that a correct output of the level is not
possible due to a too low supply voltage, it switches to error mode and sets the current
supply to 3.6 mA (independent of the error current settings made).
6. Faults
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”.
For contact details see chapter 1 “General information” or the back page of the
operating instructions.
The following table contains the most frequent causes of faults and the necessary
countermeasures.
5. Commissioning, operation / 6. Faults