FISCHER NK105 Bedienungsanleitung

Operating manual

NK10 ... H

Fill Level Limiter

for use in explosive areas

Gas explosion protection Zone 1 and 2

Dust explosion zone 21 and 22

09005112 BA_EN_NK10_H ST4-C 04/17

*09005112*

| Masthead FISCHER Mess- und Regeltechnik GmbH

2 / 36 BA_EN_NK10_H_ST4-C

Masthead

Manufacturer: FISCHER Mess- und Regeltechnik GmbH

Bielefelderstr. 37a

D-32107 Bad Salzuflen

Telefon: +49 5222 974 0

Telefax: +49 5222 7170

eMail: [email protected]

web: www.fischermesstechnik.de

Technical editorial team: Documentation representative: S. Richter

Technical editor: R.Kleemann

All rights, also those to the translation, reserved. No part of these instructions

may be reproduced or processed, duplicated or distributed using electronic sys-

tems or any other form (print, photocopy, microfilm or another process) without

the written consent of the company FISCHER Mess- und Regeltechnik GmbH,

Bad Salzuflen.

Reproduction for internal use is expressly allowed.

Brand names and procedures are used for information purposes only and do

not take the respective patent situation into account. Great care was taken

when compiling the texts and illustrations; nevertheless, errors cannot be ruled

out. The company FISCHER Mess- und Regeltechnik GmbH will not accept any

legal responsibility or liability for this.

Subject to technical amendments.

Version history

Rev. ST4-A 01/15 Version 1 (first edition)

Rev. ST4-B 06/16 Version 2 (Correction)

Rev. ST4-C 04/17 Version 4 (Dimensional drawings changed)

FISCHER Mess- und Regeltechnik GmbH Table of Contents

BA_EN_NK10_H_ST4-C iii

Table of Contents

1 Safety guidelines........................................................................................................................................... 4

1.1 General....................................................................................................................................................4

1.2 Personnel Qualification ...........................................................................................................................4

1.3 Risks due to Non-Observance of Safety Instructions..............................................................................4

1.4 Safety Instructions for the Operating Company and the Operator ..........................................................4

1.5 Unauthorised Modification.......................................................................................................................5

1.6 Inadmissible Modes of Operation............................................................................................................5

1.7 Safe working practices for maintenance and installation work................................................................5

1.8 Pictogram explanation.............................................................................................................................5

2 Product and functional description............................................................................................................. 6

2.1 Delivery scope.........................................................................................................................................6

2.2 Explosion hazard area classification .......................................................................................................6

2.3 Function diagram.....................................................................................................................................6

2.4 Design and mode of operation ................................................................................................................7

3 Installation and assembly ............................................................................................................................ 8

3.1 Safety guidelines .....................................................................................................................................8

3.2 Valid range ..............................................................................................................................................8

3.3 Process connection .................................................................................................................................8

3.4 Electrical connections..............................................................................................................................9

4 Commissioning ........................................................................................................................................... 11

4.1 Safety guidelines ...................................................................................................................................11

4.2 Generalities ...........................................................................................................................................11

4.3 Function test..........................................................................................................................................11

5 Servicing ...................................................................................................................................................... 12

5.1 Maintenance..........................................................................................................................................12

5.2 Transport ...............................................................................................................................................12

5.3 Service ..................................................................................................................................................12

5.4 Disposal.................................................................................................................................................12

6 Technical data ............................................................................................................................................. 13

6.1 General..................................................................................................................................................13

6.2 Application conditions............................................................................................................................13

6.3 Switch contacts .....................................................................................................................................14

6.4 Measurement accuracy .........................................................................................................................14

6.5 Directives and certificates .....................................................................................................................14

6.6 Construction design...............................................................................................................................14

7 Order Codes ................................................................................................................................................ 20

8 Attachments ................................................................................................................................................ 21

8.1 Declaration of Conformity......................................................................................................................21

8.2 Type testing certificates.........................................................................................................................23

8.3 DIN CERTCO Certification DIN 4754-3.................................................................................................31

8.4 EAC Declaration....................................................................................................................................33

1 | Safety guidelines FISCHER Mess- und Regeltechnik GmbH

4 / 36 BA_EN_NK10_H_ST4-C

1 Safety guidelines

1.1 General

WARNING This operating manual contains instructions fundamental to the installation, op-

eration and maintenance of the device that must be observed unconditionally. It

must be read by the assembler, operator and the specialized personnel in

charge of the instrument before it is installed and put into operation.

This operating manual is an integral part of the product and therefore needs to

be kept close to the instrument in a place that is accessible at all times to the

responsible personnel.

The following sections, in particular instructions about the assembly, commis-

sioning and maintenance, contain important information, non-observance of

which could pose a threat to humans, animals, the environment and property.

The instrument described in these operating instructions is designed and manu-

factured in line with the state of the art and good engineering practice.

1.2 Personnel Qualification

The instrument may only be installed and commissioned by specialized person-

nel familiar with the installation, commissioning and operation of this product.

Specialized personnel are persons who can assess the work they have been

assigned and recognize potential dangers by virtue of their specialized training,

their skills and experience and their knowledge of the pertinent standards.

WARNING For explosion-proof models the specialized personnel must have received spe-

cial training or instruction or be authorized to work with explosion-proof instru-

ments in explosion hazard areas.

1.3 Risks due to Non-Observance of Safety Instructions

Non-observance of these safety instructions, the intended use of the device or

the limit values given in the technical specifications can be hazardous or cause

harm to persons, the environment or the plant itself.

The supplier of the equipment will not be liable for damage claims if this should

happen.

1.4 Safety Instructions for the Operating Company and the Operator

The safety instructions governing correct operation of theinstrument must be

observed. The operating company must make them available to the installation,

maintenance, inspection and operating personnel.

Dangers arising from electrical components, energy discharged by the medium,

escaping medium and incorrect installation of the device must be eliminated.

See the information in the applicable national and international regulations.

Please observe the information about certification and approvals in the Tech-

nical Data section.

The instrument must be decommissioned and secured against inadvertent re-

operationif a situation arises in which it must be assumed that safe operation is

no longer possible. Reasons for this assumption could be:

▪ evident damage to the instrument

▪ failure of the electrical circuits

▪ longer storage outside the approved temperature range.

▪ considerable strain due to transport

FISCHER Mess- und Regeltechnik GmbH Safety guidelines | 1

BA_EN_NK10_H_ST4-C 5 / 36

Repairs may be carried out by the manufacturer only.

A professional single conformity inspection as per DIN EN 61010, section 1,

must be carried out before the instrument can be re-commissioned. This in-

spection must be performed at the manufacturer's location. Correct transport

and storage of the instrument are required.

1.5 Unauthorised Modification

Modifications of or other technical alterations to the instrument by the customer

are not permitted. This also applies to replacement parts. Only the manufac-

turer is authorised to make any modifications or changes.

1.6 Inadmissible Modes of Operation

The operational safety of this instrument can only be guaranteed if it is used as

intended. The instrument model must be suitable for the medium used in the

system. The limit values given in the technical data may not be exceeded.

The manufacturer is not liable for damage resulting from improper or incorrect

use.

1.7 Safe working practices for maintenance and installation work

The safety instructions given in this operating manual, any nationally applicable

regulations on accident prevention and any of the operating company's internal

work, operating and safety guidelines must be observed.

The operating company is responsible for ensuring that all required mainten-

ance, inspection and installation work is carried out by qualified specialized per-

sonnel.

1.8 Pictogram explanation

DANGER Type and source of danger

This indicates a direct dangerous situation that could lead to death or serious

injury (highest danger level).

a) Avoid danger by observing the valid safety regulations.

WARNING Type and source of danger

This indicates a potentially dangerous situation that could lead to death or ser-

ious injury (medium danger level).

a) Avoid danger by observing the valid safety regulations.

CAUTION Type and source of danger

This indicates a potentially dangerous situation that could lead to slight or seri-

ous injury, damage or environmental pollution (low danger level).

a) Avoid danger by observing the valid safety regulations.

NOTICE Note / advice

This indicates useful information of advice for efficient and smooth operation.

2 | Product and functional description FISCHER Mess- und Regeltechnik GmbH

6 / 36 BA_EN_NK10_H_ST4-C

2 Product and functional description

2.1 Delivery scope

▪ NK10 according to specification (see order code)

▪ Operating Instructions

2.2 Explosion hazard area classification

The fill level limiter NK10 … H can be used in areas at risk of explosion from

flammable gases or vapours Zone 1 and Zone 2.

The identification as per Directive 94/9/EC is:

II 2 G Ex ib c IIC T6 Gb

The fill level limiter NK10 … H can be used in areas at risk of explosion from

flammable dust Zone 21 and Zone22.

The identification as per Directive 94/9/EC is:

II 2 D Ex tb c IIIC T80 °C Db

WARNING Installation regulations

The respective installation instructions must be observed for every application

case.

2.3 Function diagram

2 3

8 7

approx. 10 mm

approx. 60 mm

Illustration1: Function diagram

1 Swimmer 2 Swimmer rod

3 Metal bellows 4 Test button

5 Switch lever 6 Micro-switch S1

7 Cable screw connection 8 Flange and counter-flange

9 Welding socket 10 Tank

FISCHER Mess- und Regeltechnik GmbH Product and functional description | 2

BA_EN_NK10_H_ST4-C 7 / 36

2.4 Design and mode of operation

The swim system of the fill level limiter is contained in the fluid-filled reservoir

(expansion tank). The swimming motions generated by changes in the fill level

are transmitted directly to the micro-switch S1 by a swimmer rod sealed in a

stainless-steel bellows. The fulcrum of the swimmer rod is located outside of

the pressure chamber.

There is also a test button outside the pressure chamber with which a function

check as per DIN 4754-3 can be run without lowering the fill level. When

pressed, the body of the swimmer is moved against its buoyancy.

The factory default switching point of micro-switch S1 is set so that it switches

when the swimmer rod is horizontal. The optional warning switch S2 switches

approx. 2.5 mm before S1.

The fill level height at which switching is triggered depends on the density of the

heat carrier. The lowest density at which a secure function is guaranteed is 0.6

kg/dm³.

When the medium has a density of 1.0 kg/dm³, the switching level is approx.

60mm below the middle of the flange or socket.

3 | Installation and assembly FISCHER Mess- und Regeltechnik GmbH

8 / 36 BA_EN_NK10_H_ST4-C

3 Installation and assembly

3.1 Safety guidelines

WARNING Non-observance of the following safety instructions

Non-observance of the following safety instructions can lead to a dangerous

situation, fatal injuries, series bodily harm or damage.

a) Avoid all risks by observing the following safety instructions.

DANGER!Falling objects

The operator must ensure that any falling objects cannot collide with the in-

stalled unit.

Steps must be taken to prevent

1. sparks being generated on impact.

2. the protection class of the casing is no longer guaranteed.

This can be realised by attaching protective covers, casings etc.

DANGER!Installation regulations

During installation and assembly, the application of specific installation regula-

tions in the respective permits must be observed (1) .

3.2 Valid range

0.8 to 1.1 bar abs

-20°C to 60°C

The EC type test is based on atmospheric conditions of 0.8 to 1.1 bar abs and

ambient or medium temperatures of -20°C to 60°C. If the pressure and temper-

ature levels differ, the operator needs to document the suitability in the explo-

sion protection document.

3.3 Process connection

The process connection may be realised by authorized and qualified special-

ized personnel.

The unit is set ex-works for horizontal installation. Only this installation position

is allowed.

Dangers caused by pressure on the instrument are to be prevented with suit-

able measures.

The flange and/or process connections are designed for a working temperature

of max. 400 °C and a working pressure of max. 20 bar.

CAUTION The data of the flange used may be lower.

Please check the actual data in the technical data section.

There are a range of flanges and welded hexagon nipples with which the device

can be installed on-site. Take care that the side of the device marked TOP

faces upwards when being installed.

NOTICE!Please check:

▪ The swimmer must be able to move freely in the vertical direction!

▪ Test the switching function using the test button.

(1) see Attachment

FISCHER Mess- und Regeltechnik GmbH Installation and assembly | 3

BA_EN_NK10_H_ST4-C 9 / 36

3.4 Electrical connections

▪ By authorized and qualified specialized personnel only.

▪ When connecting the unit, the national and international electro-technical

regulations must be observed.

▪ Disconnect the system from the mains, before electrically connecting the

device.

▪ Install the consumer-adapted fuses.

▪ Do not connect the connector if strained.

The instrument may only be installed and commissioned by specialized person-

nel familiar with the installation, commissioning and operation of this product.

Specialized personnel are persons who can assess the work they have been

assigned and recognize potential dangers by virtue of their specialized training,

their skills and experience and their knowledge of the pertinent standards.

For explosion-proof models, the specialized personnel must have received spe-

cial training or instruction or be authorized to work with explosion-proof instru-

ments in explosive areas.

The installed cables and wires must be tested with a reduced tensile force

(25%) in compliance with Section A.3.1 of the standard EN 60079-0 and may

only be used for permanent installation of operating equipment of Group II. The

operator must ensure that the cables are connected with clamps accordingly.

When laying the electrical supply lines, ensure that no short circuit between the

electrical conductors and the surroundings can occur.

A locking and unlocking system as per DIN 4754-3 must be incorporated, if the

device is used as a fill level limiter. This safety system must conform to DIN

50156 / VDDE 0116.

3.4.1 Intrinsically safe power circuits

For use in areas at risk of explosion, instruments must be connected to certi-

fied, intrinsically safe electricity circuits. The following are the limit values with

which the operating equipment can be operated. Compare these to the informa-

tion in the attached EC type testing certificate.

Contact power circuit In ignition protection type intrinsic safety EEx ib

IIC

Max. voltage Ui = 30V

Max. current Ii = 160 mA

Max. output Pi = 800 mW

The effective inner inductances and capacitances

are negligible.

The intrinsically safe power circuits are safely galvanically separated from each

other.

Recommend circuit breakers:

These separation switch devices are available as accessories.

Type Description Operating

voltage

MTL 5011 B 1-channel for contact 20 … 35 V DC

MTL 5015 2-channels for contact 20 … 35 V DC

KFA6-SR2-Ex1.WKFA6-SR2-Ex1.W 1-channel for contact 230 V AC

KFA6-SR2-Ex1.WKFA6-SR2-Ex1.W 2-channels for contact 230 V AC

3 | Installation and assembly FISCHER Mess- und Regeltechnik GmbH

10 / 36 BA_EN_NK10_H_ST4-C

123

Test button

123 456

1 Switch

(S1)

2 Switch

(S1 with warn switch S2)

PE PE PE

Illustration2: Circuit diagram

Ground connection

Illustration3: Ground connection

Connect the device to the earth to equalise the potential. The outer earth con-

nection is designed for 6.0 mm2 single-wire and 4.0 mm2 fine-wire conductors.

The potential must be equalised in every application case.

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