WIKA FFG Bedienungsanleitung
Operating instructions
Betriebsanleitung
GB
Level sensor model FFG
Niveau-Messwertgeber Typ FFG D
Level sensor, magnetostrictive measuring principle,
model FFG; ange connection
GB
D
2WIKA operating instructions level sensor model FFG
13445627.01 12/2010 GB/D/F
Operating instructions level sensor
Model FFG Page 3-22
Betriebsanleitung Niveau-Messwertgeber
Typ FFG Seite 23-42
GB
WIKA operating instructions level sensor model FFG 3
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Contents
Contents
Contents
WARNING!
Instructions on correct installation and proper operation.
Failing to comply with these instructions can lead to
malfunction of or damage.
DANGER!
Instructions which must be complied with to avoid injury or
property damage or loss of the type permit.
DANGER!
Instructions for proper electrical installation.
Information
Facts and information concerning proper operation.
1. Safety information 4
2. Description of functions and design 6
3. Area of application 9
4. Assembly 9
5. Electrical connection 13
6. Maintenance 19
7. Trouble shooting 19
8. Technical specications 20
9. Float selection 22
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4WIKA operating instructions level sensor model FFG
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1. Safety information
Please read these instructions carefully before installing and
commissioning the model FFG level sensor system.These
instructions are directed to trained personnel implemen-
ting the assembly, installation and set-up of the system.
The level sensor serves for indicating the level of liquids in
containers. Use it for no purpose other than this! No liability
will be assumed by Manufacturer for damage resulting from
use other than specied! The level sensor has been desig-
ned, manufactured and tested in accordance with the state
of art and the accepted safety regulations. Notwithstanding
this, certain risks might be involved.
The following safety instructions should, therefore, be observed:
Do not modify, supplement or change the level sensor system unless
with Manufacturer’s express approval. Unauthorized changes or
non-permitted use will result in immediate loss of warranty or liability
claims.
The installation, operation and maintenance must be performed by
expert and authorized personnel only.The required expertise must be
obtained by regular training.
It is imperative for operators, installers and servicers to comply with all
applicable safety regulations.This provision shall extend to all local
safety and accident preventing regulations not expressly referred to
herein.
The current and voltage values specied for an intrinsically safe operati-
on must be complied with.
1. Safety information
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Prior to starting operation please check all devices for their proper
connection, operability and power supply; this shall also apply to
assemblies coupled thereto.
The general operating instructions of all devices as used must be
abided by.
Measures should be taken preventing personal injuries and damage
to property from occurring in case of a defective condition of the level
sensor system.
The level sensor system must not be operated in the direct vicinity of
strong electromagnetic elds (minimum distance: 1 m).
The level sensor system must not be exposed to heavy mechanical
strain.
The maximum power and voltage values for the intrinsically safe
operation as specied in the assembling and operating instructions
should be adhered to.
The safe operation of the system with a view to
pressure and temperature of the materials as emplo-
yed shall be Operator’s responsibility.
As even in case of failure, the guide tube does not exhibit a
source of ignition there are no objections, in terms of safety,
to use the sensor (oat and guide tube) as an operating
unit of the 1/2 category with containers for combustible
uids (except for carbon disulphide and silicon-organic
compounds) under varying atmospheric conditions at
excess pressures of up to 25 bar and temperatures of
between -60 ... +250 °C.
1. Safety information
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DANGER!
Work in containers involves the danger of intoxication and
suocation. No work is allowed to be carried out unless by
taking suitable personal protective measures (e.g. respirato-
ry protection apparatus, protective outt etc.).
Danger of explosion
Inside the container, there is danger of an explosive atmos-
phere. Corresponding measures for preventing sparking
should be taken. No work is allowed in this area unless by
technically skilled sta in accordance with applicable safety
regulations.
2. Description of functions and design
The WIKA model FFG level sensor acts as a measured value transmitter
for high-accuracy, continuous level measurement of liquids and is
based on identifying the position of a magnetic oat following the
magnetostrictive measuring principle.
The design of the level sensor system is shown in gure 1 in the form
of embodiment furnished with a screwed-in element. Provided in the
probe head (1) is the area of connection and adjustment protected by
lid (2). The electrical connection is via an M16x1.5 cable gland (3) at
the top of the probe head while the earth connection (4) is at the bottom
of the probe head. Seated on the probe tube (5) for vertically adjustable
assembling purposes, within the container, is a compression tting (6)
(G 1/2, W 27) or a ange (not shown). The oat (7) serves for conti-
nuously gauging the product level or interface layer, and is held on the
probe tube by a guiding or locking ring (8) etc.
1. Safety information / 2. Description of functions ...
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The level sensor shown in gure 2 serves for the continuous
measurement of uids. To transmit the liquid level value to the sensor, a
oat is sliding on the sensor tube. The operating principle of the sensor
is based on the magnetostriction eect. The oat contains a magnet
while a wire made of magnetostrictive material is installed under tension
inside the sensor tube. The magnetic eld of the oat is twisting the
wire. A second, temporary magnetic eld is generated along the wire by
a current pulse within the wire. The superposition of the two magnetic
elds will release a mechanical wave on the wire.
At the end of the wire within the sensor head, the mechanical wave is
converted by a piezo-ceramic transducer into an electrical signal.The
starting point of the mechanical wave and, hence, the oat position is
then determined by measuring the transit time.
The results of such measurements are feasibility-tested by a microcon-
troller located in the sensor head and are then converted into a current
value by a digital analog transformer.The sensor is provided with a
2-wire connection so that the current consumption indicates the position
of the oat at the same time. The current values are restricted to a range
of between 3.5 ... 23 mA.
2. Description of functions and design
Fig. 1: Level sensor system model FFG
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8WIKA operating instructions level sensor model FFG
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2. Description of functions and design
Transport and storage
Transport and storage for level sensors are only allowed in designed
packaging.
Removal of the transportation packing and
transportation safety bolts
Carefully remove the level sensor from the transportation packing.
Please observe the warning on the shipment packing and remove all
transportation safety bolts, prior to discharging the level sensor system.
Never remove the level sensor system from the packing by applying
force to the guide tube!
Prior to assembly the safety bands are to be removed from the oats.
Make sure that all packing elements have been removed and that the
oats are free to move on the guide tube.
Fig. 2: Functional principle
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3. Area of application
The level sensor system is available for employment in varying container
heights of between 200 and 6000 mm. Flange-model or screw-model
designs are available allowing a stepless positioning within the contai-
ner, depending on the design thereof.
Probe tube and oat can be installed up to the screw element or ange
in areas exposed to danger of explosion, in which electric units of the
category 1/2 (zone 0) are required. In respect of the bypass model, the
complete system is allowed to be installed in areas exposed to danger
of explosion that require electric unit of category 2 (zone 1). The sensor
head of the level sensor can be operated at ambient temperatures
of between -40 ... +85 °C, while the sensor tube is operable within a
temperature range of between -25 ... +250 °C.The permitted process
temperatures in case of employment in zones subject to danger of
explosion that require operating units of categories 1/2 or 2, are set out
in the tables.
The technical specications set out in these operating
instructions should be observed.
4. Assembly
Assembly and servicing in areas exposed to danger of
explosion shall be in accordance with the provisions
stipulated by ElexV and the Act on Appliance Safety
and shall be in accordance with all applicable rules
of technology and the present operating instructions.
Moreover, please also observe all local safety and
accident preventing regulations that have not been
expressly mentioned in these operating instructions.
Make sure, during assembly that the probe tube is not
bent and that the oat is not exposed to shock.
The level sensor having Ex-approval must be so
mounted that the probe head is not located in the
Ex-zone 0.
3. Area of application / 4. Assembly
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10 WIKA operating instructions level sensor model FFG
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The level sensor systems, depending on the design thereof, will be
mounted into the container by means of a ange or a screw-in thread.
Make sure, prior to assembly, that the assembly port provided on
the container and the attachment means of the level sensor system
conform in size and dimension. Depending on the design of the level
sensor system, assembly thereof into the container must be externally.
Assembly must be in the vertical position.To insure a safe function,
the angle of assembly is allowed to dier from the vertical by 30° max.
The guide tube of the level sensor is to be externally introduced through
the assembly port of the container. Attachment thereof is by tightening
the screw-in thread in respect of threaded plugs; by bolting the cap nut
in respect of dairy pipe ttings; screwing in respect of ange-model
designs or closing of the locking rings (articulated clamp) in triclamp-
model clamp connections.
■
Level sensors having screw-in threads are to be screwed
across the entire thread length.
■
Level sensor systems having dairy pipe ttings are
furnished, ex factory, with suitable cap nuts.
■
Level sensor systems of ange-model design are to be
xed by suitable screws, washers and nuts.
■
Level sensor systems having clamp connections of the
triclamp model are to be secured by means of suitable
locking rings (articulated clamp).
Please observe the torque value of the screws!
4. Assembly
Suitable sealants should be used. Please make sure that the sealing
material is resistant to the uid and its vapours and to the anticipated
temperatures and pressures.
In designs having oats mounted thereon the diameters of which
exceed the core diameter of the mounting port the oats should be
removed from the guide tube prior to assembly thereof.
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