LR7024 - Capteur électronique de niveau IFM - Free user manual and instructions

USER MANUAL LR7024 IFM

• These operating instructions are a part of the product. Carefully read them before using the product.

• Keep the operating instructions for later use.

• Pass the operating instructions on to future owners or users of the product.

• Whenever you receive a supplement to these operating instructions enclose it to them. Safety instructions

• The unit must be connected by a suitably qualified electrician.

• The national and international regulations for the installation of electri- cal equipment must be observed.

• Voltage supply according to EN50178, SELV, PELV.

• The unit complies with the standard EN 50081-2 and is a class A prod- uct. The radiated energy of the microwaves is, for example, much below that of mobile phones. According to the current state of science the operation of the unit can be classified to be harmless to human health.

• Improper use or non-intended use may lead to malfunctions of the unit or to unwanted effects in your application. That is why installation, electrical connection, set-up, operation and maintenance of the unit must only be carried out by qualified personnel authorised by the machine operator. 24Function and features Applications LR70 is a compact level sensor for the detection of liquids. The unit was specially designed to meet the requirements of machine tool building. It is specially suited for monitoring coolant emulsions as well as aqueous cleaning agents in part cleaning systems. Restriction of the application area

• Only use the unit in metal tanks. Not suited for plastic tank covers.

• The unit is not suitable for oils, fats, granulates, bulk materials, acids, alkalis; it is not suitable for food and electroplating applica- tions.

• Foam, separate layers (e.g. oil on water), highly absorbing or bub- bling surfaces can lead to incorrect measurements or signal loss. Check the function by an application test. In case of signal loss, the unit displays "Err1" and switches the outputs to a defined state → page 41, output response). Functional overview Measuring principle The unit operates to the principle of guided wave radar: It measures the level using electromagnetic pulses in the nanosecond range. The pulses are transmitted by the sensor head and guided along the probe (fig. 1). When they hit the medium to be detected they are reflected and guided back to the sensor (fig. 2). The time between transmitting and receiv- ing the pulse directly relates to the travelled distance and the cur- rent level. The reference for distance measurement is the lower edge of the thread.

• The unit displays the current level and signals via two switching out- puts that the set limits have been reached or that the level is below the set limit. The setpoint and reset point values and the switching function of the outputs can be set via the user menu. For each of the two switching outputs a switch-off delay (max. 5 s) can be set (e.g. for specially long pump cycles).

• The unit can be installed in tanks of different sizes. 3 probe lengths are available. To adapt to the tank height, it is also possible to short- en the probe. The unit can be set to the new probe length via the user menu.

• The zone between tank bottom and lower edge of the measuring probe can be entered as offset value (OFS). Thus display and switch points refer to the real level.

• The display unit can be set: cm or inch..

• The unit can be reset to the factory settings.

• The response of the outputs in case of a fault is adjustable. If a fault is detected or if the signal quality is below a minimum value, the outputs pass into the safe state (→ page 37, parameters FOU1 and FOU2).

• Housing rotatable by 360° for orientation after mounting.

• Probe rotatable by 360° for easier mounting / removal of the probe. To ensure the unit functions correctly, certain installation conditions must be adhered to. Read the following chapter (mounting) carefully and fol- low the instructions. 26Mounting There are 3 mounting options:

1. Screw in a G¾ process connection in the tank lid.

2. Installation in the tank lid using a flange plate (e.g. for tanks with

3. Installation in an open tank using a fixture.

ATTENTION: In all cases the unit needs a metal surface to transfer the measured signals (transfer plate). On 1 and 2: For installation in closed metal tanks, the metal lid serves as a transfer plate (R). The lower edge of the thread should be flush with the mount- ing environment. Use seals or washers (D) to reach the required height. When using the ifm flange plates (→ page 31) flush installation is ensured.

DOn 3: For installation in open metal tanks, the unit must be mounted using a metal fixture. It serves as a transfer plate (R). Minimum size: 150 x 150 mm for a square fixture, 150 mm diameter for a circular fixture. If possible, mount the unit in the middle of the fixture. The distance D2 must be min. 40 mm. Installation location / installation environment

• The following minimum distances between the probe and tank walls, objects in the tank (B), tank bottom and other level sensors must be adhered to:

40mm• For tank walls which are not straight, steps, supports or other struc- tures in the tank a distance of 50 mm to the tank wall must be adhered to.

• For installation in pipes the inside pipe diameter (d) must be min. 100 mm. Only use metal pipes.

• For installation in connection pieces the connection piece diameter (d) must be min. 50 mm. The height of the connection piece (h) must not exceed 40 mm.

• The maximum level must not exceed the blocking distance (BD = 40 mm). If it is exceeded by more than 10 mm, mea- surement errors and error messages can occur. Arrange for a spout to avoid this prob- lem.

BDAdaptation of the probe The sensors are supplied with probes in different lengths (L): LR7022: L = 240 mm LR7023: L = 450 mm LR7024: L = 700 mm The probes can be shortened to adapt to different tank heights. The minimum permissible probe length Lmin is 150 mm. Proceed as follows:

1. Mark the desired length (L).

2. Unscrew the probe from the unit.

3. Shorten the probe. Ensure that the probe length is not below the

minimum permissible length (15 cm / 6 inch).

4. Remove all burrs and sharp edges.

5. Screw the probe to the unit.

Recommended tightening torque: 4 Nm.

6. Set the new probe length during set-up (→ page 36, menu point:

LEnG). Notes: Probes are also available as accessories: E43203 (240 mm), E43204 (450 mm), E43205 (700 mm). Every LR70 type sensor can be combined with any of the indicated probes. For ease of mounting and removal the probe can be rotated with respect to the thread (process connection) without restriction. Even if rotated several times by 360° there is no risk of damage to the sensor.

• For installation of the unit you need a bore hole in the tank lid. The bore hole must have a minimum diameter (d) to enable sufficient transfer of the measured signal to the probe. The diameter depends on the wall thickness of the tank lid:

• The flange plate is mounted with the flat surface showing to the tank and fixed with screws. Place the sensor seal (A) and the adapter seal (B).

• After mounting, the sensor housing can be aligned. It can be rotat- ed with respect to the thread (process connection) without restric- tion. Even if rotated several times by 360° there is no risk of dam- age to the sensor. The following flange plates are available as accessories: Flange plate 73 - 90 / G¾, aluminium ................. order no. E43201 Flange plate 65 - 80 / G¾, aluminium ................. order no. E43202 They are suitable for a maximum tank pressure of 0.5 bar.

Wall thickness [mm] 1...5 5...8 8...11 Bore hole diameter [mm] 30 40 55Electrical connection The unit must be connected by a suitably qualified electrician. The national and international regulations for the installation of electrical equipment must be observed. Voltage supply according to EN50178, SELV, PELV. Disconnect power before connecting the unit as follows:

OUT1 (operating output)Programming Timeout: If no button is pressed for 15s during the setting procedure, the unit returns to the Run mode with unchanged values. Locking / Unlocking: The unit can be electronically locked to prevent unwanted adjustment of the set parameters: Press both pushbuttons for 10s (until is displayed). To unlock: Press both pushbuttons for 10s (until is displayed). Units are delivered from the factory in the unlocked state. With the unit in the locked state is indicated when you try to change parameter values. The unit can be programmed before or after installation.

Mode/Enter Set Mode/Enter Set Mode/Enter Set Press the Mode/Enter button several times until the respective parameter is displayed. Press the Set button and keep it pressed. The current parameter value flashes for 5s, then the value is increased* (incremental by pressing briefly or scrolling by holding pressed). Press the Mode/Enter button briefly (= acknowledgement). The parameter is displayed again, the set parameter value becomes effective.

Change more parameters: Start again with step 1. Finish programming: Wait for 15s or press the Mode/Enter button until the current measured value is indicated again. *Decrease the value: Let the display of the parameter value move to the maximum setting value. Then the cycle starts again at the minimum setting value.Controls and indicating elements

MFor programming carry out the following steps in the indicated order. 1 Access the extended functions

• Press the Mode/Enter button until EF is displayed.

• Press the Set button. The first parameter of the extend- ed menu is now displayed. You can access the corre- sponding parameter value by pressing the Set button again. Pressing the Mode/Enter button accesses the fol- lowing parameters. 2 Selection of the display unit Set the required display unit: cm / inch. Select the display unit before setting values for the para- meters SPx, rPx, LEnG, OFS. This avoids rounding errors generated internally during the conversion of the units and enables exact setting of the values. Setting at the factory: Uni = cm. 3 Setting of the probe length This setting is only necessary if the probe length differs from the delivered length. On delivery: LEnG = probe length L (see scale drawing page 41).

• Determine the actual probe length (measured from the lower edge of the thread to the probe end). Round this value to 5 mm / 0.2 inch.

• Activate the parameter LEnG. Enter the new value. For the setting range of the probe length please refer to the table on page 38 4 Setting of the offset value The zone between tank bottom and lower edge of the measuring probe can be entered as offset value (OFS). Thus display and switch points refer to the real level. Setting at the factory: OFS = 0. The setting values OFS are indicated in the table on page

ParameterStep Programming5 Setting of the switching parameters SP1: setpoint 1 = upper limit value at which the switch- ing output OUT1 changes its switching status. rP1: reset point 1 = lower limit value at which the switch- ing output OUT1 changes its switching status. OU1: switching function for the switching output OU1. 4 settings can be selected: hysteresis (H..) or win- dow function (F..)as normally open (.no) or normal- ly closed (.nc). SP2: setpoint 2 = upper limit value at which the switch- ing output OUT2 changes its switching status. rP2: reset point 2 = lower limit value at which the switch- ing output OUT2 changes its switching status. OU2: switching function for the switching output OU2. 4 settings can be selected: hysteresis (H..) or win- dow function (F..)as normally open (.no) or normal- ly closed (.nc). Setting ranges for SPx and rPx → page 38. Note: If the upper setpoint is used as an overflow pro- tection, the setting OUx = Hnc (nc function) is recom- mended. The principle of normally closed operation ensures that wire break or cable break is also detected 6 Setting of the switch-off delay dr1: switch-off delay for the switching output OUT1 dr2: switch-off delay for the switching output OUT2

• Setting range: 0...5 s in steps of 0.2 s. The switch-off delay is only effective when setting the switching function hysteresis (OUx = H..). 7 Response of the outputs in case of a fault FOU1: Wrong response for the switching output OUT1 FOU2: Wrong response for the switching output OUT2 2 settings can be selected:

• On = output switches ON in case of a fault.

• OFF = output switches OFF in case of a fault. Factory setting: FOU1 / FOU2 = OFF. Faults are: faulty hardware, too low a signal quality. Overflow is not considered to be a fault!

ENGLISH ParameterStep ProgrammingReset to factory settings Resets all settings to the state on delivery. Before the fac- tory reset check the possible effects on your application!

• Press the "Mode/Enter" button until rES is displayed

• Press the "Set" button and keep it pressed until "- - - -" is displayed,

• Press the "Mode/Enter" button briefly. The display then returns to rES. Setting range for the probe length (applies to all LR70 type units) The probe can be replaced. Probes are available as accessories in different lengths. Setting range for OFS (applies to all LR70 type units) Setting range for SPx, rPx *L = probe length [cm] on delivery; ∆L = increments The values apply to the probe length on delivery and OFS = 0.

• rPx is always smaller than SPx. Reducing the value for SPx to a value ≤ rPx also shifts the position of rPx.

If the difference between rPx and SPx is small (approx. 3 x increment), increasing rPx also increases SPx.

• If the difference between rPx and SPx is great, rPx remains at the set value

Setting range in steps of

LR7023 (L = 45)* cm inch

The hysteresis keeps the switching state of the output stable if the level of the medium varies about the preset value. With the level rising, the output switches when the switch-on point has been reached (SPx). With the level falling, the output does not switch back until the level falls below the reset point rPx. The hysteresis for SPx can be adjusted: First the switch-on point is set, then the switch-off point with the requested distance. Window function (Fno, Fnc) (fig 2) The window function enables the monitoring of a defined acceptable range. When the level of the medium varies between the switch-on point (SPx) and the switch-off point (rPx), the output is switched (win- dow function / NO) or not switched (window function / NC). The width of the window can be set by means of the difference between SPx and rPx. SPx = upper value, rPx = lower value.

HncInstallation and set-up / Operation After mounting, wiring and programming check whether the unit operates correctly. Operating and fault indication: Initialisation after power on. Level indication. During operation: level below the active zone. During programming: Feedback during factory reset: all parameters reset to factory setting". Maximum measuring range is reached or exceeded. "FULL" and the indication of the maximum level alternate every second (= warning overflow). Unit electronically locked, programming not possible. For unlocking press the two programming buttons for 10 s. Feedback: unit is unlocked / programming is possible again. Fault in the electronics (the unit must be replaced). - Measured signal below the safe evaluation range. Clean the probe and the process connection. Check mounting (the mini- mum distances may not have been adhered to). - The level exceeded the block distance by more than 10 mm. Reduce the level, attach a spout if possible. - The level reaches the state "empty" or "full" more quickly than allowed (plausibility check). Possible causes: cleaning or main- tenance of the probe or tank, contact with the probe when switched on. Flashing: short circuit in the switching output 1, 2. Flashing: short circuit in both switching outputs. Carry out a reset (power off and on again) after rectifying the fault and to reset the error message.

• The parameter names are scrolled with each pressing of the "Mode/Enter" button.

• When the "Set" button is pressed briefly, the corresponding para- meter value is displayed for 15s. Output response in different operating states Technical data

• If the level is below rP1, output 1 switches until liquid is refilled. If SP1 is reached again, output 1 switches back.

• If the level is above SP2, output 2 switches. If the level falls below rP2 or if there is a wire break, output 2 switches back.

• By setting SP1 the maximum level can be controlled/monitored: The value of SP1 determines up to which level (max) is to be refilled. When the maximum level is reached, this is signalled by the LED OUT1 going out and output 1s witching off.

Switching output 1: prewarning slightly above rP1 (to suppress wave movements) below preset level → prewarning, start refilling hysteresis function, normally closed (Hnc) Switching output 2: alarm min. value reached again → alarm reset below min. value → alarm hysteresis function, normally open (Hno)

• If SP1 is exceeded, output 1 switches (submersible pump ON). When the level is below rP1 again the output switches back (submersible pump OFF).

• If SP2 is exceeded or if there is a wire break, output 2 switches off.

ENGLISH Switching output 1: control to empty vessel upper value exceeded → submersible pump ON lower value reached → submersible pump OFF hysteresis function, normally open (Hno) Switching output 2: overflow protection maximum value exceeded → alarm slightly below SP2 (to suppress wave movements) hysteresis function, normally closed (Hnc)

• If the level is below rP1, output 1 switches until liquid is refilled. If SP1 is reached again, output 1 switches back.

• If the level is below rP2 or above SP2 or if there is a wire break, output 2 switches OFF (→ alarm).

• The logical operation between the outputs 1 and 2 indicates whether there is overflow or the actual level is below the minimum level. - Overflow: output 1 and output 2 switched off. - Below min. value: output 1 switched on and output 2 switched off.

Scale drawing L = probe length A = active zone LR7022 LR7023 LR7024 cm inch