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0102
ISO9001
MANUAL
Oil Level Sensor
KVF-104-PF
PROCESS AUTOMATION
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Oil Level Sensor KVF-104-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"
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Oil Level Sensor KVF-104-PF
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Contents
1 Safety................................................................................... 2
1.1 General safety instructions ............................................................................2
1.2 Used Symbols...............................................................................................3
1.3 Declaration of Conformity..............................................................................3
1.4 Intended use .................................................................................................4
1.5 Delivery, Transport and Storage ....................................................................4
1.6 Installation and Commissioning ....................................................................5
1.7 Operation......................................................................................................6
1.8 Maintenance.................................................................................................6
1.9 Repair...........................................................................................................6
1.10 Disposal........................................................................................................6
2 Product Specifications....................................................... 7
2.1 Function ........................................................................................................7
2.2 Layout and dimensions .................................................................................7
2.3 Product programm ........................................................................................8
3 Installation........................................................................... 9
3.1 Mounting in oil/petrol separators...................................................................9
3.2 Connection .................................................................................................10
4 Operation........................................................................... 11
4.1 Emptying/Disposing of the Container..........................................................11
5 Maintenance and Repair.................................................. 12
5.1 Sensor test..................................................................................................12
6 Troubleshooting................................................................ 13
6.1 Sensor Maintenance...................................................................................13
7 Technical specifications .................................................. 14
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Safety
1Safety
1.1 General safety instructions
Responsibility for planning, assembly, commissioning, operation, maintenance,
and dismounting lies with the plant operator.
Installation and commissioning of all devices must be performed by a trained
professional only.
Protection of operating personnel and the system is not ensured if the product is
not used in accordance with its intended purpose.
Laws and regulations applicable to the usage or the intended purpose must be
observed. 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 Declaration of Conformity, Certificate of Compliance, Statement of
Conformity, EC-type-examination certificate and data sheets are an integral part of
this document.
The data sheet contains the electrical data of the Declaration of Conformity, the
Certificate of Compliance and the EC-type-examination certificate.
The documents mentioned are available from http://www.pepperl-fuchs.com or
contact your local Pepperl+Fuchs representative.
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Safety
1.2 Used Symbols
Safety-relevant Symbols
Danger!
This symbol indicates an imminent danger.
Non-observance will result in personal injury or death.
Warn ing!
This symbol indicates a possible fault or danger.
Non-observance may cause personal injury or serious property damage.
Caution!
This symbol indicates a possible fault.
Non-observance could interrupt the device and any connected systems and
plants, or result in their complete failure.
Informative Symbols
Note!
This symbol brings important information to your attention.
Action
This symbol indicates a paragraph with instructions.
1.3 Declaration of Conformity
All products were developed and manufactured under observance of the
applicable European standards and guidelines.
Note!
A Declaration of Conformity can be requested from the manufacturer.
The product manufacturer, Pepperl+Fuchs GmbH, 68307 Mannheim, has a
certified quality assurance system that conforms to ISO 9001.
ISO9001
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Safety
1.4 Intended use
The oil level sensor KVF-104-PF (referred to as "sensor" in the following section)
is a suspended sensor for monitoring oil layer thickness in oil/petrol separators.
The KVF-104-PF must always be connected to an ATEX-approved, intrinsically
safe warning device of type LAL-SRW (see product program).
The device is only approved for appropriate and intended use. Ignoring these
instructions will void any warranty and absolve the manufacturer from any liability.
Use the device only within the specified ambient temperature range.
Individually accessible non-grounded metal parts can become electrostatically
charged. The determined capacitance exceeds the required value according to
IEC/EN 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.
1.4.1 Marking
Pepperl+Fuchs GmbH
Lilienthalstrasse 200, 68307 Mannheim, Germany
Oil level sensor KVF-104-PF
DEMKO 07 ATEX 142586X
II 1G Ex ia IIB T3
1.5 Delivery, Transport and Storage
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.
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Safety
1.6 Installation and Commissioning
1.6.1 Installation des Sensors
The sensor may be installed in potentially explosive zone 0 in accordance with
Directive 94/9/EC (ATEX). The sensor must not be installed in places with
potentially aggressive vapors.
The sensor and warning device must be free of voltage during installation and
maintenance. The warning device must only be connected to the supply voltage
after complete mounting and connection of the sensors.
The sensor has IP68 protection and is weather- and oil-resistant. It can therefore
be installed in oil/petrol separators.
When installing the device in oil/petrol separators, observe the permissible
ambient temperature in the range from -20 °C ... 60 °C (253 K ... 333 K).
1.6.2 Installation in connection with intrinsically safe circuits
Installation of the intrinsically safe power circuits of the devices is permitted in
potentially explosive zones, whereby, in particular, safe separation from all nonintrinsically safe power circuits must be guaranteed.
The intrinsically safe current circuits must be installed according to valid setup
regulations.
For the interconnection of the intrinsically safe field devices and the intrinsically
safe power circuits of the associated devices, the respective maximum values of
the field device and the associated device with regard to explosion protection
must be observed (proof of intrinsic safety). EN 60079-14/IEC 60079-14 must be
observed.
If the used sensors have not a tested dielectric strength (500 V according to
IEC/EN 60079-11) between the external conductive parts and the intrinsically safe
circuits, it must be assumed that the sensors and the corresponding intrinsically
safe circuits have electrical contact with each other. In this case verification of
intrinsic safety must include the possibility of the interconnection of all intrinsically
safe circuits.
1.6.3 Sensor Cables
Sensor cables must not be installed in cable or conductor bundles together with
other current circuits. Avoid installing sensor cables parallel to other cables that
may transmit interfering signals, which impair the sensor signal and thus the alarm
function. The sensor itself must not be grounded.
If you extend the sensor cable, observe the applicable ATEX specifications with
regard to color, quality and durability. Use unshielded cables.
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Safety
1.7 Operation
1.7.1 Caution - emulsions
An oil/petrol separator is a device for separating oil from water. Situations may
arise in which the oil can not be separated because an emulsion has formed. An
emulsion is a relatively stable mixture of oil and water. Sensors can not detect oil if
emulsions with a high water content have formed. Always contact the oil/petrol
separator manufacturer if there is any doubt as to whether the oil has been
separated from the water before the liquid is drained to the sewage system.
1.8 Maintenance
For operation of oil/petrol separators, there may be standards, directives or laws
that define regular system or sensor tests. Check the operation of the sensor at
least twice a year and more frequently in the event of unfavorable environmental
conditions.
When the oil/petrol separator is being emptied (disposal), the sensor must always
be washed and dried. The sensor must not be cleaned with caustic fluids. A badly
contaminated sensor can trip a wrong alarm or, in certain circumstances, fail to
trip an alarm.
1.9 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 Disposal
Disposal of devices and their packaging material must be performed in
compliance with the applicable laws and guidelines of the corresponding country.
The devices do not contain batteries which need to be disposed of separately
from the products.
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3
1
5
4
2
138
25
Ø31.6
Product Specifications
2 Product Specifications
2.1 Function
The sensor has an integrated electronic circuit which, via an oscillator circuit,
emits a weak HF signal that changes depending on whether the sensor element is
surrounded by water or by oil/air. The sensor is capable of distinguishing between
air and water, and between water and oil, but not between air and oil.
2.2 Layout and dimensions
The sensor consists of three sections (see illustration):
• The lower stainless steel section (1) provides electrical connection to the
liquid.
• The middle section (2) is electrically isolated.
• The upper section made of stainless steel forms the switch contact (3).
Figure 2.1
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1 Lower section with laser marking
2 Middle section
3 Upper section
4 Cable
5 Switching point
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Product Specifications
2.3 Product programm
Warning device
Description Typ e co de
Intrinsically safe warning device, 230 V AC LAL-SRW
Sensors
Description Typ e co de
Overflow sensor for detecting excessively high fluid
level
Oil level sensor for detecting thickness of oil level KVF-104-PF
Accessories
Description Typ e co de
Cable connector IP68 for one sensor LAL-SK2
Mounting set for one sensor NVO5-B
NVF-104/34-PF
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Installation
3 Installation
3.1 Mounting in oil/petrol separators
Read the chapter on Safety and, in particular, the section on Installation and
Commissioning (see chapter 1.6.1) before installing the sensor.
Warn ing!
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.
During installation, observe the instructions of the oil/petrol separator
manufacturer. Always ensure that the sensor suspension device remains
constantly at the correct height. If possible, ensure that the suspension device is
mounted in a location that can be reached from the separator access shaft so that
it is possible to raise the sensor during separator emptying (disposal) or
maintenance of the oil/petrol separator.
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.
With a correct fluid level, the sensor must be immersed a few centimeters in the
fluid. How far it is immersed depends on the type of oil/petrol separator, the
design and the capacity. The lower section made of stainless steel must always
be immersed in the fluid. The switch point (see chapter 2.2, dimension drawing,
position 5) of the sensor is located between the isolated middle section and the
upper metal section.
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Installation
1 Layer thickness
2 Alarm level
3 Sensor KVF-104-PF (new model)
4 Sensor KVF-103-PF (old model)
5 Water
6 Oil
3.2 Connection
Read the chapter on Safety and, in particular, the section on Installation and
Commissioning (see chapter 1.6.1) before connecting the sensor.
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.
6
5
3
4
1
2
When making the connection, ensure the polarity of the sensor cables is correct.
The loop resistance of the extension cable should not exceed 20 for the sensor.
Note!
Further information on connection of the sensors to the warning device is
available in the manual of the warning device LAL-SRW.
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Operation
4Operation
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.
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Maintenance and Repair
5 Maintenance and Repair
5.1 Sensor test
Te s t fr eq u e n cy
The sensor is maintenance-free. However, to guarantee perfect operation of the
complete alarm system check the operation of the sensor at least once a year, or
more frequently in the event of unfavorable environmental conditions.
Check of normal situation
1. Remove the sensor from the oil/petrol separator.
2. Wash and dry the sensor.
3. Take the sensor in your hand (without gloves).
4. Only touch the upper and lower metal section (see chapter 2.2, dimension
drawing, position 1 and 3)
The green "SYSTEM OK" LED lights up or flashes at the warning device.
Check of alarm situation
1. Remove the sensor from the oil/petrol separator.
2. Wash and dry the sensor.
3. Suspend the sensor freely in midair.
The "HIGH OIL LEVEL" LED lights up and, if applicable, an acoustic
signal sounds.
Note!
Further information on the LED alarm messages is available in the manual of the
warning device LAL-SRW.
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Troubleshooting
6Troubleshooting
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.
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Technical specifications
7 Technical specifications
Power supply
Rated voltage 13 V DC
Directive conformity
Electromagnetic compatibility
Directive 2004/108/EC EN 61326-1:2013 (industrial locations),
Conformity
Degree of protection IEC 60529:2001
Ambient conditions
Ambient temperature -20 ... 60 °C (-4 ... 140 °F)
Mechanical specifications
Degree of protection IP68
Connection cable, length 5 m (15 ft), 2 x 0.75 mm2
Material stainless steel
Mass approx. 580 g
Dimensions 31.6 x 138 mm
Data for application in connection with Ex-areas
EC-Type Examination Certificate DEMKO 07 ATEX 142586X
Group, category, type of protection,
temperature class
Vol tag e U
Current I
Power P
Internal capacitance C
Internal inductance L
Capacitance 50 pF for accessible non-grounded metal
Directive conformity
Directive 94/9/EC EN 60079-0:2012+A11:2013,
i
i
i
i
i
EN 55011:2009+A1:2010
cross section
II 1G Ex ia IIB T3
13 V
140 mA
1.05 W
200 nF
0.2 mH
parts
EN 60079-11:2012
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Subject to modifications
Copyright PEPPERL+FUCHS • Printed in Germany
www.pepperl-fuchs.com
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
277659 DOCT-0937F
06/2015
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