PROCESS AUTOMATION MANUAL Overflow sensor NVF-104/34-PF ISO9001 0102
Overflow sensor NVF-104/34-PF With regard to the supply of products, the current issue of the following document is applicable: The General Terms of Delivery for Products and Services of the Electrical Industry, published by the Central Association of the Electrical Industry (Zentralverband Elektrotechnik und Elektroindustrie (ZVEI) e.v.) in its most recent version as well as the supplementary clause: "Expanded reservation of proprietorship"
Contents 1 Safety... 2 1.1 Validity...2 1.2 Target Group/Personnel...2 1.3 Reference to Further Documentation...2 1.4 Symbols Used...3 1.5 Marking...3 1.6 Intended Use...4 1.7 Improper Use...4 1.8 Mounting/Installation...4 1.9 Operation, Maintenance, Repair...5 1.10 Delivery, Transport, Disposal...5 2 Product Specifications... 6 2.1 Function...6 2.2 Components...7 2.3 Design and Dimensions...8 3 Installation... 9 3.1 Mounting the Sensors...9 3.2 Connecting the Sensor...12 4 Operation... 13 4.1 Emptying/Disposing of the Container...13 5 Maintenance and Repair... 14 5.1 Function Testing...14 6 Troubleshooting... 15 6.1 Sensor Maintenance...15 7 Technical Specifications... 16 7.1 Overflow Sensor NVF-104/34-PF...16-1
Safety 1 Safety 1.1 Validity The chapter Safety is valid as instruction manual. Specific processes and instructions in this document require special precautions to guarantee the safety of the operating personnel. 1.2 Target Group/Personnel The plant owner is responsible for its planning, installation, commissioning, operation, maintenance and disassembly. Mounting, installation, commissioning, operation, maintenance and disassembly of any devices may only be carried out by trained, qualified personnel. The instruction manual must be read and understood. 1.3 Reference to Further Documentation Laws, standards, or directives applicable to the intended use must be observed. In relation to hazardous areas, Directive 1999/92/EC must be observed. The corresponding data sheets, declarations of conformity, EC Type-examination certificates, certificates and Control Drawings if applicable (see data sheet) are an integral part of this document. You can find this information under www.pepperl-fuchs.com. Due to constant revisions, documentation is subject to permanent change. Please refer only to the most up-to-date version, which can be found under www.pepperl-fuchs.com. 2 -
Safety 1.4 Symbols Used This document contains information that you must read for your own personal safety and to avoid property damage. Depending on the hazard category, the warning signs are displayed in descending order as follows: Safety-relevant symbols Danger! This symbol indicates a warning about an immediate possible danger. In case of ignoring the consequences may range from personal injury to death. Warning! This symbol indicates a warning about a possible fault or danger. In case of ignoring the consequences may cause personal injury or heaviest property damage. Caution! This symbol indicates a warning about a possible fault. In case of ignoring the devices and any connected facilities or systems may be interrupted or fail completely. Informative symbols Note! This symbol brings important information to your attention. 1.5 Marking Action This symbol indicates a paragraph with instructions. Overflow sensor Pepperl+Fuchs GmbH Lilienthalstrasse 200, 68307 Mannheim, Germany NVF-104/34-PF EPS 11 ATEX 1 352 X II 1G Ex ia IIB T3-3
Safety 1.6 Intended Use The overflow sensor is a component of an alarm system. The overflow sensor must always be connected to one of the following warning devices: Warning device LAL-SRW Warning device LAL-SRW3 Warning device NVO5-11 Warning device NVO5-111 Warning device NVO5-151-** The devices are only approved for appropriate and intended use. Ignoring these instructions will void any warranty and absolve the manufacturer from any liability. The device must only be operated in the ambient temperature range specified. Individually accessible non-grounded metal parts can become electrostatically charged. The determined capacitance exceeds the required value according to IEC/ 60079-0. The determined capacitance is specified in the technical data. Information on electrostatic hazards can be found in the technical specification IEC/TS 60079-32-1. 1.7 Improper Use Protection of the operating personnel and the overall system is not ensured if the product is not being used according to its intended purpose. The equipment is not suitable for isolating signals in high current applications unless this is noted separately in the corresponding datasheet. 1.8 Mounting/Installation Prior to mounting, installation, and commissioning of the device you should make yourself familiar with the device and carefully read the instruction manual. The installation instructions in accordance with IEC/ 60079-14 must be observed. The device must not be installed at locations where corrosive vapors may be present. The sensor itself must not be grounded. Circuits of type of protection "Ex i" (intrinsically safe) which have been operated with circuits of other type of protections must not be used as "Ex i" circuits afterwards. Circuits of intrinsically safe apparatus can be led into hazardous areas, whereby special attention must be paid to maintaining separation distances to all non-intrinsically safe circuits according to the requirements in IEC/ 60079-14. 4 -
Safety The respective peak values of the field device and the associated apparatus with regard to explosion protection should be considered when connecting intrinsically safe field devices with intrinsically safe circuits of associated apparatus (verification of intrinsic safety). Make sure to observe IEC/ 60079-14 and IEC/ 60079-25. 1.9 Operation, Maintenance, Repair The devices must not be repaired, changed or manipulated. If there is a defect, the product must always be replaced with an original device. 1.10 Delivery, Transport, Disposal Check the packaging and contents for damage. Check if you have received every item and if the items received are the ones you ordered. Keep the original packaging. Always store and transport the device in the original packaging. Always store the device in a clean and dry environment. The permitted storage temperature (see data sheet) must be considered. Disposing of devices, packaging material, and possibly contained batteries must be in compliance with the applicable laws and guidelines of the respective country. - 5
Product Specifications 2 Product Specifications 2.1 Function The NVF-104/34-PF overflow sensor, referred to here simply as the sensor, is a component of an alarm system. The sensor is installed in a suspended position in oil/petrol separators and detects fluid overflows and backwater. The sensor can also be used as a filter monitor for coalescence filters. A liquid overflow can occur if: The coalescence filter is dirty. The automatic closure device is blocked. Another situation causes to contamination by the oily liquid or overflow. The overflow sensor is a PTC thermistor sensor, energized via an intrinsically safe relay, and can differentiate between liquid and air: When the PTC thermistor is surrounded by air, it heats up. At the same time, the ohmic resistance in the PTC thermistor increases as the current decreases. The intrinsically safe relay is in normal status. When the PTC thermistor is surrounded by liquid, it does not heat up. The current increases. The intrinsically safe relay switches to alarm mode. Caution! The overflow sensor may malfunction or become damaged if used in pastes or paints. Pastes and paints may coagulate when heated and stick to the sensor. This will impair the sensor s properties with regard to temperature changes. As a result, the reliability and function of the sensor or the entire alarm system cannot be guaranteed. Do not use the sensor as an overflow sensor in: - Pastes or paints - Liquids with similar properties 6 -
Product Specifications 2.2 Components The alarm system can comprise the following components: Warning devices Description Intrinsically safe warning devices, 230 VAC Type code LAL-SRW* NVO5-111* NVO5-151* NVO5-11 NVO5-15 Sensor Description Overflow sensor, for detecting excessively high liquid levels Type code NVF-104/34-PF Accessories Description Cable connector for one sensor Mounting set for one sensor Type code LAL-SK2 NVO5-B - 7
Product Specifications 2.3 Design and Dimensions The overflow sensor consists of a stainless steel pipe (2). A PTC thermistor is installed in the pipe as the trip point (3). The pipe is sealed. To prevent air from becoming trapped, the pipe is fitted with a 5 mm drill hole. The sensor is equipped with a 5 m oil-resistant cable (1). 1 2 100 24 5000 3 Figure 2.1 1 Cable 2 Stainless steel tube 3 Trip point 25 Ø20 8 -
Installation 3 Installation 3.1 Mounting the Sensors Note! Before mounting the device, read the section on safety, and in particular the section on mounting/installation. Do not remove the type label. During installation, refer to the instructions provided by the manufacturer of the oil/petrol separator. The sensors are designed with IP68 protection and are therefore weather and oil resistant. 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. The oil/petrol separator can be made of various materials. We therefore recommend using the following methods to secure the device in a suspended position: If mounting the device in concrete containers, use the NVO5-B mounting set. See the figure below. If mounting the device in containers made from other materials, such as plastic or metal, use other suspension devices as appropriate, for example, screws and screw anchors. - 9
Installation 2 1 Figure 3.1 Mounting using cable connector and mounting set 1 Mounting set for one sensor NVO5-B 2 Cable connector for one sensor LAL-SK2 Mounting the Suspension Device 1. Mount the suspension device of the sensor in such a way that the defined height of the sensor is constantly maintained. See the subsequent sections. 2. Mount the suspension device of the sensor in such a way that it can be easily reached from the access shaft on the oil/petrol separator. The sensor can easily be removed when emptying, maintaining, or disposing of the oil/petrol separator. 10 -
Installation 3.1.1 Mounting the NVF-104/34-PF Overflow Sensor Positioning the Sensor 1. When mounting the sensor, position the lower edge of the sensor a few centimeters above the water zero line (normal liquid level). See the figure below. 2. Make sure that the trip point of the sensor is positioned in such a way that it is fully surrounded by liquid in the event of an overflow. The trip point is located at the height of the 5 mm drill hole on the side of the sensor. A 1 S B X L C Figure 3.2 Mounting the overflow sensor 1 NVF-104/34-PF overflow sensor A Air B Oil C Water L Water zero line (normal liquid level) S Sensor trip point X Alarm limit (maximum liquid level) - 11
Installation 3.2 Connecting the Sensor Note! Before connecting the device, read the section on safety, and in particular the section on mounting/installation. Do not remove the type label. 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. Connecting the Sensor 1. Connect the sensor to the warning device. Ensure that the polarity of the sensor cable is correct when connecting the cable. 2. Use the LAL-SK2 cable connector to extend the sensor cable. Note! Avoid routing the sensor cable parallel to other cables, as these cables may transmit interfering signals. These interfering signals may affect the sensor signal and impair the alarm function. Use unshielded 2-strand cables for each sensor. To ensure the warning device functions correctly, do not exceed the following maximum sensor cable lengths: With a cable cross section of 0.75 mm 2, the maximum cable length is 190 m. With a cable cross section of 1 mm 2, the maximum cable length is 250 m. Take the following maximum connection values into account when doing so: Total inductance: 0.4 mh Total resistance: 10 Note! Further information on connection of the sensor to the warning device is available in the warning device manuals. 12 -
Operation 4 Operation 4.1 Emptying/Disposing of the Container The sensor is a sensitive component. Please note the following information when disposing of/emptying the container: 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. Caution! Malfunction or false alarm caused by a contaminated sensor If the sensor is very dirty, this may trigger a false alarm or mean that no alarm is triggered under certain circumstances. Clean and dry the sensor when emptying/disposing of the oil/petrol separator or container. Do not clean the sensor with corrosive liquids. - 13
Maintenance and Repair 5 Maintenance and Repair 5.1 Function Testing Checking the Sensor The sensor is maintenance free. To ensure the entire alarm system functions correctly, check the function of the sensor at the following intervals: 1. Check the function of the sensor at least twice a year. 2. If the sensor is used in difficult conditions, perform this check more often. Caution! Risk of burning The sensor tip is hot. Do not touch. Checking Normal Status 1. Remove the sensor from the oil/petrol separator. 2. Wash and dry the sensor. 3. Suspend the sensor freely in air. The green "SYSTEM OK" LED flashes or illuminates on the warning device. Checking the Alarm Status Immerse the sensor in liquid. Ensure the trip point is immersed. The red "OVERFLOW ALARM" LED illuminates. Where applicable, an audible signal sounds. Note! Further information on connection of the sensor to the warning device is available in the warning device manuals. 14 -
Troubleshooting 6 Troubleshooting 6.1 Sensor Maintenance Caution! Malfunction or false alarm caused by a contaminated sensor If the sensor is very dirty, this may trigger a false alarm or mean that no alarm is triggered under certain circumstances. Clean and dry the sensor when emptying/disposing of the oil/petrol separator or container. Do not clean the sensor with corrosive liquids. Cleaning the Sensor The sensor is maintenance free. To ensure the entire alarm system functions correctly, clean the sensor at the following intervals: 1. Clean the sensor at least once a year. 2. Pay particular attention to cleaning the sensor tips of all oil, grease, and other dirt residues using a grease-dissolving cleaning agent. 3. If the sensor is used in difficult conditions, clean the sensor more often. - 15
Technical Specifications 7 Technical Specifications 7.1 Overflow Sensor NVF-104/34-PF Supply Rated voltage Conformity 24 V DC Protection degree IEC 60529 Ambient conditions Ambient temperature Mechanical specifications Protection degree -20... 50 C (-4... 122 F) IP68 Connection cable, length 5 m (15 ft), 2 x 0.75 mm 2 cross section Material Stainless steel 1.4305/AISI 303 Mass approx. 315 g Dimensions 20 x 124 mm Data for application in connection with Ex-areas EC-Type Examination Certificate EPS 11 ATEX 1352 X Group, category, type of protection, II 1G Ex ia IIB T3 temperature class Voltage U i 24 V DC Current I i 400 ma Internal capacitance C i 600 pf Internal inductance L i 0.1 mh Capacitance C 30 pf for accessible non-grounded metal parts Directive conformity Directive 94/9/EC 60079-0:2012+A11:2013, 60079-11:2012 16 -
PROCESS AUTOMATION PROTECTING YOUR PROCESS Worldwide Headquarters Pepperl+Fuchs GmbH 68307 Mannheim Germany Tel. +49 621 776-0 E-mail: info@de.pepperl-fuchs.com For the Pepperl+Fuchs representative closest to you check www.pepperl-fuchs.com/contact www.pepperl-fuchs.com Subject to modifications Copyright PEPPERL+FUCHS Printed in Germany 277634 DOCT-0936G 04/2015