WIKA KSR HLS Operating Instructions Manual

Operating Instructions
Betriebsanleitung

Magnetic Float Switch
for horizontal installation, model HLS

EN

Schwimmer-Magnetschalter
für horizontalen Einbau, Typ HLS

DE

Horizontaler Schwimmer-Magnetschalter, Typ HLS

Horizontal Magnetic Float Switch, model HLS

123250.0

3 / 06.08.2019

EN/DE

2 Operating Instructions Horizontal Magnetic Float Switch - HLS

EN

Operating Instructions, Model HLS

DE

Betriebsanleitung, Typ HLS

© 2016 WIKA Alexander Wiegand SE & Co. KG
All rights reserved. / Alle Rechte vorbehalten.
WIKA® and KSR® are registered trademarks in various countries.
WIKA® and KSR® sind geschützte Marken in verschiedenen Ländern.

Prior to starting any work, read the operating instructions!
Keep for later use!

Read the operating instructions before starting any work!
Keep them for later use!

Manufacturer contact
Manufactured by

Sales contact
Distributed by

KSR Kuebler Niveau-Messtechnik GmbH

Heinrich-Kuebler-Platz 1
69439 Zwingenberg am Neckar • Germany
Tel. [phone]
Fax [phone]
[e-mail]
www.ksr-kuebler.com

WIKA Alexander Wiegand SE & Co. KG

Alexander-Wiegand-Straße 30
63911 Klingenberg • Germany
Tel. [phone]
Fax [phone]
[e-mail]
www.wika.de

Operating Instructions Horizontal Magnetic Float Switch - HLS 3

Contents

1. General information 4

2. Design and function 5

3. Safety 6

4. Transport, packaging and storage 12

5. Commissioning, operation 13

6. Faults 21

7. Maintenance and cleaning 22

8. Dismounting, return and disposal 23

9. Specifications 24

4 Operating Instructions Horizontal Magnetic Float Switch - HLS

1. General information

 The horizontal magnetic float switches described in the operating

instructions are designed and manufactured in accordance with the
current state-of-the-art. During production, all components are subject
to strict quality and environmental criteria. Our management systems
are certified in accordance with ISO 9001.

 These operating instructions provide information on how to use the

unit. Compliance with all specified safety instructions and work
instructions are a prerequisite for working safely.

 Compliance with the local applicable accident prevention regulations

and general safety regulations for the area of use of the unit is
required.

 The operating instructions are a component of the product and must

be kept in the immediate vicinity of the unit where they are accessible
to the technicians at all times. Pass on the operating instructions to
subsequent users or owners of the unit.

 The technicians must read and understand the operating instructions

prior to starting any work.

 The general terms and conditions from the sales documents apply.
 Technical changes reserved.
 Additional information:

- Internet address: www.ksr-kuebler.com or www.wika.com

Operating Instructions Horizontal Magnetic Float Switch - HLS 5

3

2. Design and function

2.1 Functional description

Horizontal magnetic float switches work on the floating principle with
magnetic transmission. The float is attached to a supported, swivelling
lever and moves with the level of the medium being measured. When a
preset switch point is reached, a reed contact (inert gas contact) within
the contact pipe is actuated by the magnet inside the lever. By using a
permanent magnet and a reed contact the switching operation is non­contact, free from wear and needs no power supply. The functioning of
the horizontal float switch is independent of foaming, conductivity,
vapours, bubble formation and vibrations. The signal processing is
universal. Direct connection to PLCs, NAMUR connections, signal
amplifiers or contact protection relays is possible.

Fig. 1: Type: HLS

2.2 Scope of delivery

Compare the contents of the delivery with the delivery slip.

1. Terminal housing

2. Cable gland

3. Flange

4. Float

5. Swivelling
1

2 4 5

6 Operating Instructions Horizontal Magnetic Float Switch - HLS

3. Safety

3.1 Symbols

DANGER!

... indicates an immediately hazardous situation which
might result in death or severe injuries if it is not
avoided.

WARNING!

... indicates an potentially hazardous situation which
might result in death or severe injuries if it is not
avoided.

CAUTION!

... indicates an potentially hazardous situation which
might result in light or minor injuries or property or
environmental damages if it is not avoided.

INFORMATION

... highlights useful tips and recommendations and
information for efficient and fault-free operation.

3.2 Proper intended use

The HLS horizontal magnetic float switches are solely intended for
monitoring the liquid level of fluids. The area of use is based on the
technical performance limits and materials.

 The fluids must not be contaminated nor contain coarse particles

nor tend to crystallize. It must be ensured that the magnetic float
switch materials that come into contact with the media are
sufficiently resistant to the monitored medium. Not suitable for
dispersion, abrasive fluids, highly viscous media and paints.

 Compliance with the usage conditions specified in the operating

instructions is required.

Operating Instructions Horizontal Magnetic Float Switch - HLS 7

 Do not operate the unit in direct proximity of ferro-magnetic

environments (distance min. 50mm).

 Do not operate the unit in direct proximity of strong

electromagnetic fields or in direct proximity of facilities that can
be impacted by magnetic fields (distance min. 1m).

 The magnetic float switches may not be subjected to strong

mechanical stresses (impact, bending, vibrations). The unit is
exclusively designed and constructed for the intended use
described here and may only be used accordingly.

 The switching points of the magnetic float switch cannot be

adjusted.

 These instructions are intended for technicians who execute the

installation and calibration.

 Compliance with the relevant safety regulations for the use is

required.

 Compliance with the technical specifications in these operating

instructions is required. Improper use or operation of the unit
outside the technical specifications requires immediate shut­down and inspection by an authorized WIKA service technician.

Claims of any kind due to improper use are excluded.

DANGER!

When working on containers, there is a risk of poisoning
or suffocation. Work may only be performed using
suitable personal safety equipment (e.g. respiratory
protection, protective clothing, etc.).

8 Operating Instructions Horizontal Magnetic Float Switch - HLS

3.3 Improper use

Any use that exceeds the technical performance thresholds or that is
incompatible with the materials is considered improper use.

WARNING!
Injury due to improper use

Improper use of the unit can result in hazardous
situations and injuries.

 Do not modify the unit without authorization
 Do not use the unit in potentially explosive areas.

Any use beyond the proper intended use or any other use is considered
improper use.

Do not use this unit in safety or emergency off equipment.

3.4 Responsibility of the operator

The unit is used in the industrial sector. The operator is therefore subject
to statutory obligations with respect to occupational safety.

Compliance with the safety instructions in these operating instructions
and the applicable safety, accident prevention and environmental
protection regulations for the area of use of the unit is required.

In order to safely work on the unit, the operator must ensure

 the operating personnel is regularly trained in all matters

pertaining to occupational safety, first aid and environmental
conservation and is familiar with the operating instructions and, in
particular, the safety instructions contained therein

 the unit is suitable for the application in accordance with the

proper intended use (check for improper use).

After check, improper use is excluded.

Operating Instructions Horizontal Magnetic Float Switch - HLS 9

3.5 Personnel qualification

WARNING!
Risk of injury due to insufficient qualifications

Improper use can result in significant personal injury and
property damages.

 The activities described in these operating

instructions may only be performed by specialist
technicians with the following qualifications.

Specialist personnel

The specialist personnel authorized by the operator is capable of
executing the described work and autonomously detect potential
hazards due their technical training, knowledge of measuring and control
technology and their experience and knowledge of country-specific
regulations, applicable standards and guidelines.

3.6 Personal safety equipment
The personal safety equipment serves to protect the technicians against

hazards that might impact the safety or health while working. When
executing the various tasks on and with the unit, the technicians must
wear personal safety equipment.

Comply with warning signs posted in the work area regarding
personal safety equipment!

The required personal safety equipment must be provided by the
operator.

10 Operating Instructions Horizontal Magnetic Float Switch - HLS

3.7 Signs, safety markings
Name plate

1. Model, designation

2. Instrument code

3. Article number

4. Switching power

5. Ingress protection per IEC/EN 60529

6. Measuring point number

7. Serial number

Symbols

Before mounting and commissioning the instrument,
ensure you read the operating instructions!

Operating Instructions Horizontal Magnetic Float Switch - HLS 11

4. Transport, packaging and storage

4.1 Transport

Check the magnetic float switch for potential transport damage.
Immediately report obvious damage.

CAUTION!
Damage due to improper transport

Improper transport can result in significant property
damages.

 When unloading packages upon delivery and for

internal facility transport, proceed carefully and
comply with the symbols on the packaging.

 For internal facility transport, follow the

instructions in Chapter 4.2 “Packaging and
storage”

4.2 Transport and storage

Remove packaging immediately prior to assembly. Keep the packaging
as it provides optimum protection during transport (e.g. changing
installation location, repair shipment).

12 Operating Instructions Horizontal Magnetic Float Switch - HLS

5. Commissioning, operation

Comply with all of the instructions on the packaging pertaining to
removing the transport locks.

Remove the magnetic float switch from the packaging carefully!
When unpacking, check all parts for external damage.

5.1 Assembly preparations

 Ensure the sealing surface of the container or the HLS is clean

and has no mechanical damage.

5.2 Assembly (see Fig. 1: Model HLS)

 Comply with the screw torques defined for pipeline construction.
 When selecting the assembly material (seals, screws, washers

and nuts), comply with the process conditions. The seal must be
suitable with respect to the measuring material and the vapours it
emits. In addition, appropriate corrosion protection must be
ensured.

 Install the horizontal magnetic float switch in accordance with the

design (flange or threading).

 Magnet-operated float switches for horizontal operation must be

installed as shown in fig. 2.

 Use the screws and nuts suitable for the flange for flange types.
 Fit a suitable gasket (4) for sealing. Make sure it is installed in the

right position. (The float must be tilted downwards in the
unactivated state).

 When installing in the union, make sure that the tilting of the float

is not affected.”).

Operating Instructions Horizontal Magnetic Float Switch - HLS 13

Figure 2: Installation Type: HLS

Installation in ferromagnetic supports, negatively impacts the
functionality of the switch.

Risk of property damage due to improper switching
behaviour of the reed contact.
The horizontal float switch must be installed so the contact
tube is outside a ferromagnetic support.

5.3 Commissioning

Switch on the supply voltage of the connected control unit, fill the
container and check the functionality of the magnetic float switch
switching points. The functional test can also be performed manually on
a disassembled switch.

Ensure the functionality test does not initiate any unintended
processes.

14 Operating Instructions Horizontal Magnetic Float Switch - HLS

5.3.1 Electrical connection

The electrical connection must be established in accordance
with the application construction regulations in the country of
installation and may only be performed by specialist
personnel.
To increase the service life of the contacts, operation using a
contact protection relays is recommended.

The electrical connection must be established in accordance
with the connection diagram on the respective switch.
(Designs with only one opening or closing contact do not have
connection diagrams).
The cable bushing (2) on the connection casing (1) must be
sealed.

Operating the magnetic float switch on inductive or capacitive
loads can result in the destruction of the Reed contact. This
can result in a malfunction of the downstream control unit and
personal injuries or property damages.
With inductive loads, the magnetic float switches must be
protected using an RC link in accordance with the Appendix or
a free-wheel diode.

Operating Instructions Horizontal Magnetic Float Switch - HLS 15

With capacitive loads, cable lengths exceeding 50m or the
connection to the process control systems with capacitive
inputs, a protective resistance of 22 Ohm or 47 Ohm (for
10VA contacts) must be switched in series in order to limit
the peak current.
When connecting to time relays, a resistance of 220 Ohm

must be installed in series.

An overload of the magnetic float switch may result in the
destruction of the installed Reed contact. This can result in a
malfunction of the downstream control unit and personal
injuries or property damages. Compliance with the maximum
values for the switching capacity specified in the “Technical
Data” Chapter and in the data sheet HLS... is required.

For horizontal magnetic float switches with a connection
cable without a protective ground connection, the switch
may conduct current in the event of a malfunction.
Touching it can result in severe bodily injury or fatal
injuries. These switches can only be operated with
protective low voltage in accordance with VDE0100 (e.g.
with a KSR contact protection relay) or must be installed
so the magnetic float switch is electrically connected to
the potential equalizer.