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LevelControl Basic 2
Installation/Operating Manual
Legal information/Copyright
Installation/Operating Manual LevelControl Basic 2
All rights reserved. The contents provided herein must neither be distributed, copied, reproduced,
edited or processed for any other purpose, nor otherwise transmitted, published or made available to a
third party without the manufacturer's express written consent.
Subject to technical modification without prior notice.
Contents
Glossary .................................................................................................................................................. 5
1 General.................................................................................................................................................... 6
1.1 Principles ........................................................................................................................................................... 6
1.2 Target group..................................................................................................................................................... 6
1.3 Other applicable documents............................................................................................................................ 6
1.4 Symbols ............................................................................................................................................................. 6
2 Safety ...................................................................................................................................................... 7
2.1 Key to safety symbols/markings....................................................................................................................... 7
2.2 General.............................................................................................................................................................. 7
2.3 Intended use ..................................................................................................................................................... 7
2.4 Personnel qualification and personnel training ............................................................................................. 8
2.5 Consequences and risks caused by non-compliance with this manual ......................................................... 8
2.6 Safety awareness .............................................................................................................................................. 8
2.7 Software Changes............................................................................................................................................. 8
3 Transport/Temporary Storage/Disposal............................................................................................... 9
3.1 Checking the condition upon delivery ............................................................................................................ 9
3.2 Transport........................................................................................................................................................... 9
3.2.1 Transport .............................................................................................................................................. 9
3.3 Storage .............................................................................................................................................................. 9
3.4 Disposal ........................................................................................................................................................... 10
4 Description............................................................................................................................................ 11
4.1 General description ........................................................................................................................................ 11
4.2 Designation..................................................................................................................................................... 11
4.3 Name plate...................................................................................................................................................... 11
4.4 Design ............................................................................................................................................................. 12
4.4.1 Basic Compact (BC)............................................................................................................................. 12
4.4.2 Basic Control Cabinet (BS) ................................................................................................................. 12
4.4.3 ATEX devices ...................................................................................................................................... 13
4.5 Technical data................................................................................................................................................. 13
4.5.1 Electrical data..................................................................................................................................... 13
4.5.2 Dimensions and weights.................................................................................................................... 14
4.5.3 Technical specifications for sensors .................................................................................................. 14
5 Installation at Site ................................................................................................................................ 16
5.1 Safety regulations........................................................................................................................................... 16
5.2 Checks to be carried out prior to installation............................................................................................... 16
5.3 Installing the control unit .............................................................................................................................. 16
5.4 Electrical connection ...................................................................................................................................... 17
5.5 Connecting the pneumatic pressure measuring equipment ....................................................................... 17
6 Operation.............................................................................................................................................. 18
6.1 Control panel .................................................................................................................................................. 18
6.1.1 Indicators ............................................................................................................................................ 18
6.1.2 Display ................................................................................................................................................ 19
6.1.3 Navigation keys.................................................................................................................................. 19
6.2 Manual-0-automatic selector switch ............................................................................................................. 20
6.3 Service interface ............................................................................................................................................. 20
6.4 Commissioning / start-up / shutdown............................................................................................................ 22
6.4.1 Preparing commissioning/start-up .................................................................................................... 22
6.4.2 Commissioning/start-up..................................................................................................................... 22
6.4.3 Shutdown ........................................................................................................................................... 22
6.5 Control panel .................................................................................................................................................. 23
6.5.1 Displaying measured value parameters............................................................................................ 23
6.5.2 Setting parameters ............................................................................................................................ 24
6.5.3 Acknowledging alerts and warnings ................................................................................................ 28
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Contents
4 of 68 LevelControl Basic 2
Glossary
Glossary
ATEX
The acronym ATEX is the French abbreviation for
"Atmosphère explosible" and refers to the two
European Union (EU) directives covering the area
of explosion protection: ATEX Equipment Directive
2014/34/EU (also referred to as ATEX 95) and ATEX
Workplace Directive 1999/92/EC (also referred to
as ATEX 137).
DOL starting
For low power ratings (usually up to 4 kW), the
three-phase motor is connected directly to the
mains voltage.
Star/delta starting
For starting large three-phase squirrel-cage motors
(5.5 kW and above). Prevents voltage dips and
fuses from tripping. Used if direct starting would
result in a high starting current.
LevelControl Basic 2 5 of 68
1 General
1 General
1.1 Principles
This operating manual is supplied as an integral part of the type series and variants
indicated on the front cover. The manual describes the proper and safe use of this
equipment in all phases of operation.
The name plate indicates the type series, the main operating data and the serial
number. The serial number uniquely describes the product and is used as
identification in all further business processes.
In the event of damage, immediately contact your nearest KSB service centre to
maintain the right to claim under warranty.
1.4 Symbols
Table 2: Symbols used in this manual
Symbol Description
✓ Conditions which need to be fulfilled before proceeding with the
step-by-step instructions
⊳ Safety instructions
⇨ Result of an action
⇨ Cross-references
1. Step-by-step instructions
2.
Note
Recommendations and important information on how to handle
the product
1) Optional
6 of 68 LevelControl Basic 2
2 Safety
2 Safety
All the information contained in this section refers to hazardous situations.
! DANGER
2.1 Key to safety symbols/markings
Table 3: Definition of safety symbols/markings
Symbol Description
! DANGER DANGER
This signal word indicates a high-risk hazard which, if not avoided,
will result in death or serious injury.
! WARNING WARNING
This signal word indicates a medium-risk hazard which, if not
avoided, could result in death or serious injury.
CAUTION CAUTION
This signal word indicates a hazard which, if not avoided, could
result in damage to the machine and its functions.
Explosion protection
This symbol identifies information about avoiding explosions in
potentially explosive atmospheres in accordance with EU Directive
2014/34/EU (ATEX).
General hazard
In conjunction with one of the signal words this symbol indicates a
hazard which will or could result in death or serious injury.
Electrical hazard
In conjunction with one of the signal words this symbol indicates a
hazard involving electrical voltage and identifies information about
protection against electrical voltage.
Machine damage
In conjunction with the signal word CAUTION this symbol indicates
a hazard for the machine and its functions.
2.2 General
This operating manual contains general installation, operating and maintenance
instructions that must be observed to ensure safe operation of the system and
prevent personal injury and damage to property.
The safety information in all sections of this manual must be complied with.
The operating manual must be read and understood by the responsible specialist
personnel/operators prior to installation and commissioning.
The contents of this operating manual must be available to the specialist personnel
at the site at all times.
Information attached directly to the product must always be complied with and kept
in a perfectly legible condition at all times. This applies to, for example:
▪ Markings for connections
▪ Name plate
The operator is responsible for ensuring compliance with all local regulations not
taken into account in this operating manual.
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2 Safety
8 of 68 LevelControl Basic 2
3 Transport/Temporary Storage/Disposal
3 Transport/Temporary Storage/Disposal
3.2 Transport
The control unit must be shut down for transport.
3.2.1 Transport
CAUTION
Improper transport
Damage to the control unit!
▷ The control unit must always be transported properly and in its original
packaging.
▷ For transport observe the transport instructions on the original packaging.
▷ Do not throw the control unit.
1. Upon receipt, unpack the control unit and check for in-transit damage.
2. Report any in-transit damage to the manufacturer immediately.
3. Dispose of packaging material in accordance with local regulations.
3.3 Storage
If the ambient conditions for storage are met, the function of the control unit is
safeguarded even after a prolonged period of storage.
CAUTION
Damage during storage by humidity, dirt or vermin
Corrosion/contamination of the control unit!
▷ For outdoor storage cover the (packed or unpacked) control unit and
accessories with water-proof material.
LevelControl Basic 2 9 of 68
3 Transport/Temporary Storage/Disposal
3.4 Disposal
NOTE
Due to certain components it contains, the device is classified as special waste and
meets RoHs 2011/65/EC requirements.
Once decommissioned, the device must be properly disposed of in accordance with
local regulations.
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4 Description
4 Description
4.2 Designation
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4 Description
4.4 Design
1
3
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4 Description
NOTE
The switchgear assemblies are not explosion-proof, and therefore must only be
operated outside potentially explosive atmospheres.
Both variants (BC and BS) are available as ATEX versions. In ATEX mode, the pump is
reliably prevented from being activated if the fluid level drops below the minimum
level (to prevent dry running and, therefore, sources of ignition). This also applies to
manual mode or forced start-up via a telecontrol system. (Please refer to the
information given in section 6.5.5.)
The control unit is always located outside the potentially explosive atmosphere.
CAUTION
The rated current must not be exceeded.
Higher currents and power ratings are available on request.
LevelControl Basic 2 13 of 68
4 Description
NOTE
LevelControl Basic 2 can only be used with TN mains and TT mains as standard.
On request, special versions can be supplied for IT mains.
4 .. 20 mA
▪ Two-wire and three-wire connection
▪ Input resistance ≤ 300 ohms
▪ ATEX-compliant versions in BS housing
▪ For ATEX-compliant version incl. 1 analog intrinsic safety barrier, type Stahl
9002/13-280-110-001
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4 Description
Process inputs
▪ 1 external alarm input, 24 V
▪ 1 remote acknowledgement, 24 V
Process outputs
▪ 1 volt-free signalling output changeover contact (250 V, 1 A, NO/NC contact)
▪ 1 signalling output (12.6 to 13.2 V, max. 200 mA), e.g. for connecting a horn,
alarm combination or alarm strobe light (12 V)
Rechargeable battery
Connection for rechargeable battery, for mains-independent power supply of:
▪ Electronics
▪ Sensors
▪ Alarm equipment
LevelControl Basic 2 15 of 68
5 Installation at Site
5 Installation at Site
DANGER
Incorrect installation
Danger to life!
▷ The control unit must be installed in a flood-proof location.
▷ Never install the control unit in potentially explosive atmospheres.
▷ Integration in external control system: observe the directives for low-voltage
switchgear and controlgear assemblies.
Place of installation
The place of installation must meet the following requirements:
▪ No potentially explosive atmosphere
▪ Well ventilated
▪ Level
▪ Clean
▪ Sufficient stability
▪ No direct sunlight
▪ Protected from weather
▪ Flood-proof
▪ Sufficient clearance for ventilation, installation, removal and operation
Ambient conditions
The ambient conditions specified in the following table must be observed:
NOTE
Contact the manufacturer if the device is to be used under ambient conditions
other than those described above.
16 of 68 LevelControl Basic 2
5 Installation at Site
DANGER
Unintentional contact with live parts
Danger of death from electric shock!
▷ De-energise the mains connection.
▷ Take steps to ensure that the mains connection cannot be re-energised
unintentionally.
CAUTION
Improper electrical connection
Damage to the control unit/control cabinet!
▷ Check the type of current and voltage of the mains.
▷ Observe the wiring diagrams.
ü The mains voltage matches the rated voltage specified on the name plate.
1. Route the cables through the cable glands.
2. Make sure that the seals are properly positioned and tighten the cable glands
(strain relief).
3. Connect the control unit/cabinet in accordance with the wiring diagram
(ð Section 10, Page 59) and in line with the application.
CAUTION
Condensate accumulation in connecting tube
Incorrect pressure reading!
▷ Always install the connecting tube with a continuously falling slope.
▷ Shorten the connecting tube, if necessary, to allow condensate to drain at all
times.
1. Run the connecting tube of the measuring device into the control unit through
an unused cable gland (M16).
2. Push the connecting tube onto the connecting element and make sure that it is
secure.
3. Make sure that the seal is properly positioned and tighten the cable gland
(strain relief).
LevelControl Basic 2 17 of 68
6 Operation
6 Operation
DANGER
Unintentional starting of pumps
Risk of injury: Limbs can be pulled into or crushed by machinery!
▷ Make sure that nobody is within the immediate, hazardous vicinity of the
pumps.
▷ Make sure that all piping is properly installed and that the fluid handled cannot
escape.
NOTE
This section provides information about a control unit for two pumps. The control
unit for one pump is operated in the same way; pump-specific steps shall only be
carried out once in this case.
3
ESC OK
4
6.1.1 Indicators
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6 Operation
6.1.2 Display
The following information is displayed:
Fig. 5: Display
1 Parameter
2 Parameter/measured value
3 Alert
Esc
Escape key:
▪ Cancel entry without saving it.
▪ When entering numbers: Go to the previous digit.
▪ Move up one menu level.
OK
OK key:
▪ Confirm settings.
▪ Confirm a menu selection.
▪ When entering numbers: Go to the next digit.
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6 Operation
NOTE
The "KSB Service Tool" software can be downloaded from the KSB web site or
obtained as Service CD-Rom (see price list).
20 of 68 LevelControl Basic 2
6 Operation
LevelControl Basic 2 21 of 68
6 Operation
To operate the device via the service interface, carry out the following steps:
1. Connect the computer and device by means of an RS 232 cable.
2. Start the Service Tool.
For more information, please refer to the ServiceTool manual.
6.4.2 Commissioning/start-up
CAUTION
Incorrect commissioning/start-up
Damage to property!
▷ Ensure that all local applicable regulations and directives – particularly the
machinery and low-voltage directives – are fulfilled.
▷ Install a line protection device in the supply cable. For the line protection
required please refer to the attached logic diagram.
▷ Before commissioning, check all connected cables against the wiring diagram.
6.4.3 Shutdown
Short-term shutdown
1. Set the manual-0-automatic selector switches for both pumps to "0".
ð Both pumps are switched off.
ð The control unit remains operational (read measured values, set parameters).
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6 Operation
Long-term shutdown
1. Set the manual-0-automatic selector switches for both pumps to "0".
2. Switch off the power supply.
station
Single-
pump
pump
Dual-
1-1-1 Level (Analog) Fill level in millimetres (if analog sensors are ✘ ✘
used): pneumatic, bubbler system, 4 .. 20 mA
1-1-2 Level (Digital) Switching levels if float switches or digital ✘ ✘
level switches are used
1-1-3 Line Voltage Line voltage in volts ✘ ✘
1-2-1 Operating Hours Pump 1 Operating hours of pump 1 ✘ ✘
1-2-2 Start Count Pump 1 Number of starts of pump 1 ✘ ✘
1-3-1 Operating Hours Pump 2 Operating hours of pump 2 - ✘
1-3-2 Start Count Pump 2 Number of starts of pump 2 - ✘
2-1-1 Pending Messages List of acknowledged alerts ✘ ✘
LevelControl Basic 2 23 of 68
6 Operation
NOTE
The parameters that you can call up depend on the operating mode and
measurement method. Only parameters that are relevant to the current operating
mode and measurement method are displayed.
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6 Operation
CAUTION
Incorrect operation
Damage to property!
▷ To protect the device, the parameter settings can only be changed from float
switch/digital level switch to 4 .. 20 mA if the peak load switching point has not
responded.
▷ Drain the tank in manual mode, if necessary.
OK
2. Use the arrow keys to select the required parameter number.
3. Confirm the parameter number with OK .
ð The parameter value is displayed immediately.
4. Set the parameter value using the arrow keys:
OK
5. Confirm your entries with OK: The parameter value is saved.
ð The parameter number is displayed.
Esc
6. Abort the input with ESC : The parameter value remains unchanged.
ð The parameter number is displayed.
Esc
7. Press ESC to return to the measured values.
LevelControl Basic 2 25 of 68
6 Operation
station
station
Single-
pump
pump
Dual-
3-3-2 Stand-by Pump Switchover between dual-pump 0 = dual-pump station - ✘
and stand-by mode with peak-load
operation (factory
setting)
1 = stand-by pump, one
pump ON at high water
2 = stand-by pump, two
pumps ON at high water
3-3-3 Draining/Filling Switchover between draining 0 = draining (factory ✘ ✘
and filling (if float switches or setting)
digital level switches are used) 1 = filling
3-3-4-1 Level Pumps OFF Stop level of pumps in 250 mm (factory setting) 4 .. 20 mA 4 .. 20 mA
millimetres with pneumatic,
bubbler, 4 .. 20 mA
3-3-4-2 Level Base Load ON Start level of base load pump in 400 mm (factory setting) 4 .. 20 mA 4 .. 20 mA
millimetres with pneumatic,
bubbler, 4 .. 20 mA
3-3-4-3 Level Peak Load ON Start level of peak load pump 500 mm (factory setting) - 4 .. 20 mA
in millimetres with pneumatic,
bubbler, 4 .. 20 mA
3-3-4-4 Level High Water Level for high water alert in 600 mm (factory setting) 4 .. 20 mA 4 .. 20 mA
millimetres with pneumatic,
bubbler, 4 .. 20 mA
3-3-5-3 Stop Delay Stop delay of base load pump 0 seconds (factory ✘ ✘
in seconds setting)
3-3-6 ATEX Mode Activation of ATEX mode: Tank 0 = OFF ✘ ✘
cannot be drained below the 1 = ON
stop level.
3-4-2 Measurement Float switches, digital level 0 = float switch (with ✘ ✘
Method switches, or 4 .. 20 mA hysteresis; factory
setting)
1 = digital level switch
(without hysteresis)
2 = 4..20 mA sensor
3-4-3-1 Level at 4 mA Measured value at 4 mA in 200 mm (factory setting) 4 .. 20 mA 4 .. 20 mA
millimetres
3-4-3-2 Level at 20 mA Measured value at 20 mA in 1000 mm (factory 4 .. 20 mA 4 .. 20 mA
millimetres setting)
3-7-1 Check Run ON/OFF Functional check run OFF or ON 0 = functional check OFF ✘ ✘
(time-dependent) (factory setting)
1 = functional check
performed after idle
period of one week
3-8-1 Factory Reset Restores the factory settings 1 = load factory settings ✘ ✘
4-1-1 Firmware Version Firmware version - ✘ ✘
NOTE
The parameters for 4 .. 20 mA are not displayed until parameter 3-4-2 has been set
to value 2 = 4 .. 20 mA.
26 of 68 LevelControl Basic 2
6 Operation
station
station
Single-
pump
pump
Dual-
3-3-2 Stand-by Pump Switchover between dual-pump 0 = dual-pump station - ✘
and stand-by mode with peak-load
operation (factory
setting)
1 = stand-by pump, one
pump ON at high water
2 = stand-by pump, two
pumps ON at high water
3-3-4-1 Level Pumps OFF Stop level of pumps in 250 mm (factory setting) ✘ ✘
millimetres with pneumatic,
bubbler, 4 .. 20 mA
3-3-4-2 Level Base Load ON Start level of base load pump in 400 mm (factory setting) ✘ ✘
millimetres with pneumatic,
bubbler, 4 .. 20 mA
3-3-4-3 Level Peak Load ON Start level of peak load pump 500 mm (factory setting) - ✘
in millimetres with pneumatic,
bubbler, 4 .. 20 mA
3-3-4-4 Level High Water Level for high water alert in 600 mm (factory setting) ✘ ✘
millimetres with pneumatic,
bubbler, 4 .. 20 mA
3-3-5-3 Stop Delay Stop delay of base load pump 0 s (factory setting) ✘ ✘
in seconds
3-3-6 ATEX Mode Activation of ATEX mode: Tank 0 = OFF ✘ ✘
cannot be drained below the 1 = ON
stop level.
3-4-4-1 Level of Bell Distance of pressure bell (lower 200 mm (factory setting) ✘ ✘
edge) from bottom of tank
(offset). Factory setting:
200 mm
3-7-1 Check Run ON/OFF Functional check run OFF or ON 0 = functional check OFF ✘ ✘
(time-dependent) (factory setting)
1 = functional check
performed after idle
period of one week
3-8-1 Factory Reset Restores the factory settings 1 = load factory settings ✘ ✘
4-1-1 Firmware Version Firmware version - ✘ ✘
NOTE
Set the stop delay (parameter 3-3-5) in such a way that the liquid level drops below
the open pressure bell to allow the air cushion in the measuring tube to build up
again and that pumps operated in ATEX mode are fully covered by the liquid at all
times.
LevelControl Basic 2 27 of 68
6 Operation
NOTE
Alerts with a higher priority prevail over alerts with a lower priority. For instance,
alert A1 has a higher priority than alert A2.
Esc
1. If necessary, exit the screen for setting parameters by pressing ESC .
ð The alert with the highest priority is displayed.
OK
2. Acknowledge the alert with OK :
ð Horn/buzzer is deactivated
ð If the alert is still present, it is entered in the alerts list (2-1-1).
ð The next alert (if any) is displayed.
3. Rectify the cause of the fault:
ð If necessary, call up the parameter settings by pressing OK or ESC .
The following alerts and warnings can be displayed:
28 of 68 LevelControl Basic 2
6 Operation
No.
Prio.
Type Acknowledgement Description Action
NOTE
The service interval is deactivated by default and can be set via the Service Tool.
Esc
1. If no measured value number (P 1-X-X) is displayed, press ESC (more than once if
necessary).
2. Use the arrow keys to select the alerts list (P 2-1-1).
ð The most recent entry is displayed automatically after 1.5 seconds. The next
entry is displayed after another 1.5 seconds.
Esc
3. To return to the screen in which you can select a measured value, press ESC.
NOTE
The ATEX mode can also be enabled on non-ATEX models. However, this will not
ensure ATEX-compliant operation of non-ATEX models.
NOTE
In ATEX mode, too, the stop delay will result in the fluid being pumped off to a
level below the set stop level. Make sure that the pumps are always covered by the
fluid pumped.
LevelControl Basic 2 29 of 68
6 Operation
NOTE
In ATEX mode, the redundant high water float switch will trigger an alert if the
high water level is exceeded and the level measuring device is defective. For safety
reasons, the pump can only be operated if the presence of an adequate liquid cover
is ensured by the existing basic level measurement.
NOTE
If you want to clean the tank or carry out similar tasks, ATEX mode must be
deactivated.
DANGER
Risk of explosion due to dry running in non-ATEX mode
Danger to life!
▷ Only deactivate ATEX mode when you are sure that the tank does not contain a
potentially explosive atmosphere.
▷ Reactivate ATEX mode once you have completed all the necessary work.
1. Make sure that the tank does not contain a potentially explosive atmosphere.
2. Set the manual-0-automatic selector switches for both pumps to "0".
3. Set parameter P 3-3-6 to "0".
4. Pump the tank dry in manual mode .
NOTE
The rechargeable batteries must be replaced every five years to ensure that the
device operates reliably in battery mode.
Use original spare parts only.
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6 Operation
NOTE
When retrofitting the control unit with the rechargeable battery installation
option, it is not sufficient to insert the rechargeable battery/batteries only. A
rechargeable battery retrofit kit is required, which not only comprises the
rechargeable battery/batteries but also an electronic recharging unit as well as
some fastening material.
LevelControl Basic 2 31 of 68
7 Application Examples
7 Application Examples
3
B
A 2
1
32 of 68 LevelControl Basic 2
7 Application Examples
4
C
B 3
A 2
1
LevelControl Basic 2 33 of 68
7 Application Examples
7.1.3 Dual-pump station as stand-by pump: Draining via one float switch
3
B
2
A
1
Fig. 13: Dual-pump station as stand-by pump: Draining via one float switch
A Float switch base load 1 Both pumps OFF
B Float switch high water (optional) 2 Base load pump ON
3 High water alert
▪ 3-3-2 = 1 base load pump
ON
▪ 3-3-2 = 2 both pumps ON
The second pump is operated as a stand-by pump in case the first pump fails
(redundant system). The pumps are alternated after each pumping cycle.
34 of 68 LevelControl Basic 2
7 Application Examples
C 3
B 2
A 1
LevelControl Basic 2 35 of 68
7 Application Examples
D 4
C 3
B 2
A 1
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7 Application Examples
7.2.3 Dual-pump station as stand-by pump: Draining via two digital level switches
C
C 3
B 2
A 1
Fig. 16: Dual-pump station as stand-by pump: Draining via two digital level switches
A Digital level switch OFF 1 Pump OFF
B Digital level switch base load 2 Base load pump ON
C Digital level switch high water (optional) 3 High water alert
▪ 3-3-2 = 1 base load pump
ON
▪ 3-3-2 = 2 both pumps ON
The second pump is operated as a stand-by pump in case the first pump fails
(redundant system). The pumps are alternated after each pumping cycle.
LevelControl Basic 2 37 of 68
7 Application Examples
7.3.1 Single-pump station: Draining via two float switches (without hysteresis)
3
C
C
2
B
A
1
Fig. 17: Single-pump station: Draining via two float switches (without hysteresis)
A Float switch OFF 1 Pump OFF
B Float switch base load 2 Base load pump ON
C Float switch high water (optional) 3 High water alert and pump
ON
38 of 68 LevelControl Basic 2
7 Application Examples
7.3.2 Dual-pump station: Draining via three float switches (without hysteresis)
4
D
C
3
C
C
2
B
A
1
Fig. 18: Dual-pump station: Draining via three float switches (without hysteresis)
A Float switch OFF 1 Both pumps OFF
B Float switch base load 2 Base load pump ON
C Float switch peak load 3 Both pumps ON
D Float switch high water (optional) 4 High water alert and pump
ON
The pump that is started up first is the base load pump. The pumps are alternated
after each pumping cycle to ensure even distribution of operating hours.
LevelControl Basic 2 39 of 68
7 Application Examples
7.3.3 Dual-pump station as stand-by pump: Draining via two float switches (without
hysteresis)
3
C
2
B
A
1
Fig. 19: Dual-pump station as stand-by pump: Draining via two float switches
(without hysteresis)
A Float switch OFF 1 Both pumps OFF
B Float switch base load 2 Base load pump ON
C Float switch high water (optional) 3 High water alert
▪ 3-3-2 = 1 base load pump
ON
▪ 3-3-2 = 2 both pumps ON
The second pump is operated as a stand-by pump in case the first pump fails
(redundant system). The pumps are alternated after each pumping cycle.
40 of 68 LevelControl Basic 2
7 Application Examples
NOTE
If a high water float is also used, the redundant high water float must be installed
with sufficient cable play (sufficient hysteresis). This prevents frequent pump
starting/stopping if the analog measurement fails (4 .. 20 mA / pneumatic / bubbler
control). In addition, the pumps' actual stop level can be influenced via the set stop
delay.
NOTE
In potentially explosive atmospheres, the redundant high water float must only be
used with intrinsic safety (IS) barriers.
C
3
2
A
LevelControl Basic 2 41 of 68
7 Application Examples
C 4
2
A
42 of 68 LevelControl Basic 2
7 Application Examples
C
3
2
A
LevelControl Basic 2 43 of 68
7 Application Examples
NOTE
Devices set to float switch mode at the factory can be changed to 4..20 mA sensor
with parameter 3-4-2, Measurement Method.
NOTE
The parameters that you can call up depend on the operating mode and
measurement method. Only parameters that are relevant to the current operating
mode and measurement method are displayed.
NOTE
If a high water float is also used, the redundant high water float must be installed
with sufficient cable play (sufficient hysteresis). This prevents frequent pump
starting/stopping if the analog measurement fails (4 .. 20 mA / pneumatic / bubbler
control). In addition, the pumps' actual stop level can be influenced via the set stop
delay.
NOTE
In potentially explosive atmospheres, the redundant high water float must only be
used with intrinsic safety (IS) barriers.
44 of 68 LevelControl Basic 2
7 Application Examples
B C D
5
E
C
4
3
A
2
1
LevelControl Basic 2 45 of 68
7 Application Examples
B C D 6
E
C 5
3
A
2
1
46 of 68 LevelControl Basic 2
7 Application Examples
B C D
5
E
C
3
A
2
1
LevelControl Basic 2 47 of 68
7 Application Examples
CAUTION
Changing the external alarm input
Damage to property!
▷ Make sure that the pumps stop in the event of dry running.
NOTE
The external alarm input can be used to protect the pump(s) against dry running. In
as-delivered condition, the control unit is set in such a way that the pumps are
safely stopped, regardless of the level in the tank to be filled, if there is a risk of dry
running.
3
B
2
A
Ext 1
041
040
4
5
C
48 of 68 LevelControl Basic 2
7 Application Examples
NOTE
Use floats A and B as normally open contacts only (circuit closed in upper float
position).
If the Ext alarm input (terminals 40 - 41) is used for dry running protection, a NC
float switch (circuit open in upper float position) must be used, to stop the pumps
in the event of dry running.
LevelControl Basic 2 49 of 68
7 Application Examples
4
C
3
B
2
A
Ext 1
041
040
5
6
D
NOTE
Use floats A, B and C as normally open contacts only (circuit closed in upper float
position).
If the Ext alarm input (terminals 40 - 41) is used for dry running protection, a NC
float switch (circuit open in upper float position) must be used, to stop the pumps
in the event of dry running.
50 of 68 LevelControl Basic 2
7 Application Examples
NOTE
If, with analog level measurement, the value of parameter 3-3-3 Draining/Filling is
altered, the values of parameters 3-3-4-1, Pump OFF, and 3-3-4-3, Peak Load Pump
(not shown for single-pump units), will be interchanged automatically, thus
ensuring that appropriate parameter settings are retained at all times.
LevelControl Basic 2 51 of 68
7 Application Examples
52 of 68 LevelControl Basic 2
7 Application Examples
NOTE
If, with analog level measurement, the value of parameter 3-3-3 Draining/Filling is
altered, the values of parameters 3-3-4-1, Pump OFF, and 3-3-4-3, Peak Load Pump,
will be interchanged automatically, thus ensuring that appropriate parameter
settings are retained at all times.
LevelControl Basic 2 53 of 68
7 Application Examples
8 9 10 11 12 13
+
Uh Ext Ack
Signalling output
▪ Terminal assignments
– 30 and 31
▪ Function
– For connecting external alarm equipment (e.g. horn, alarm strobe light, or
alarm combination).
– Voltage of 12.6 .. 13.2 V DC.
– Max. capacity: 200 mA.
– If a battery is used, this will continue to supply the output in the event of a
power failure. The connected alarm equipment then operates independently
of the mains supply.
External alarm
NOTE
Same as on alarm switchgears, the signalling output is only activated in the event of
high water and sensor fault. This setting can be changed using the KSB ServiceTool.
NOTE
Parameters for the external alarm can only be changed using the ServiceTool.
▪ Terminal assignments
– 40 and 41
▪ Alarm transmitter
If the Ext alarm input is used for dry running protection, a NC float switch (circuit
open in upper float position) must be used, to stop the pumps in the event of dry
running.
– Dry-running protection via float switch or sensor.
▪ Function
54 of 68 LevelControl Basic 2
7 Application Examples
NOTE
In the factory setting, the pumps are stopped when the contact closes. This setting
can be changed using the KSB ServiceTool.
Remote acknowledgement
▪ Terminal assignments
– 50 and 51
▪ Function
– The "Ack" input is used to acknowledge alerts remotely.
NOTE
If cables longer than 15 metres are to be connected to the Enable input, a coupling
relay must be fitted in the control unit and the cable must be connected to the
Enable input via the coupling relay. This prevents excessive cable losses and ensures
the correct function of the control unit.
LevelControl Basic 2 55 of 68
8 Checklist for Commissioning / Inspection and Maintenance
56 of 68 LevelControl Basic 2
9 Trouble-shooting
9 Trouble-shooting
WARNING
Carrying out work on a running pump
Risk of injury: Limbs can be pulled into or crushed by machinery!
▷ Disconnect the drive from the power supply.
▷ Take steps to ensure that the drive cannot be switched on again
unintentionally.
9.1 Trouble-shooting
WARNING
Improper work to remedy faults
Risk of injury!
▷ For any work performed to remedy faults, observe the relevant information
given in this operating manual and/or in the product literature provided by the
accessories manufacturer.
If problems occur that are not described in the following table, consultation with the
KSB customer service is required.
A Pump is running, but does not deliver
B Insufficient discharge head
C Excessive current/power input
D Vibrations and noise during pump operation
E Lifting unit frequently switches to fault mode
WARNING
The pump set may still be pressurised
Danger from escaping fluid!
▷ Release the pump pressure before carrying out maintenance work on the pump
set.
▷ Disconnect the pump set from the power supply.
Table 40: Trouble-shooting
A B C D E Possible cause Remedy
✘ ✘ - - Operating voltage is too low. Check mains voltage.
Check cable connections.
✘ - - - - Motor/pump not running due to lack of Check electrical installation (and fuses).
voltage. Fuse (230 V) or motor protection switch (400 V)
tripped.
- ✘ ✘ ✘ ✘ Wrong direction of rotation (three-phase Reverse two phases of power cable or motor
units) supply cable.
✘ ✘ - - ✘ Motor is running on two phases only (three- Check conductor voltages.
phase units). If necessary, replace defective fuse.
Check cable connections.
✘ - - - ✘ Manual-0-automatic switch set to "0". Set manual-0-automatic switch to "automatic".
✘ - - - ✘ Motor winding or electric cable are defective. Replace by new original KSB parts or contact KSB.
- ✘ - - - Water level in tank/sump too low during Check level sensor.
operation. Check parameters. If necessary, repeat
parameterisation.
LevelControl Basic 2 57 of 68
9 Trouble-shooting
58 of 68 LevelControl Basic 2
10 Wiring Diagrams
10 Wiring Diagrams
NOTE
For type BS, refer to the circuit diagrams enclosed with the control unit.
In certain cases, the pump connections may not be exactly as shown on the wiring
diagrams provided here. For this reason, also always refer to the pump's product
literature and circuit diagrams provided.
J203
J201
1 2 3
209 222 221 220 Alarm 011 013 015 017 019 031 041 051
-
2T1 4T2 6T3 14NO A2 2T1 4T2 6T3 14NO A2
L3 L2 L1 N PE PE PE 109 122 121 120 001 002 024 021 022 010 012 014 016 018 030 040 050
+
PE gn/ye
PE gn/ye
PE gn/ye
bu
bu
bn
bk
bu
bn
18
19 22
23
26
29 29 22
gn/ye
gn/ye
bn
bn
bu
bu
24
25
PE gn/ye
bk bu
21
014 014 27
Analog IN Analog IN
+24V +24V
(GND)
Fig. 31: Circuit diagram: Ama-Drainer N 301/302/303, Ama-Drainer N 358, Ama-Drainer NE 4../5.., Ama-Porter NE
1 Contactor pump 1 2 Contactor pump 2
3 Mains connections 4 Moisture monitor
3~400V, 1~230V
5 Thermal circuit breaker 6 Release
7 Volt-free alarm contact 8 Float/digital switch
9 High-water float 10 mini-Compacta/Compacta sensors
11 Connection for alarm equipment 12 External alarm input
13 Remote acknowledgement 14 Pneumatic
15 Pump 1 16 Pump 2
17 Power supply 18 High-water float
19 Float switches 20 Digital switch
21 Analog sensor 4 ... 20 mA 22 Peak load ON
23 Pump ON/OFF 24 Base load ON
25 Pumps OFF 26 Signal transmitter 12 V DC
LevelControl Basic 2 59 of 68
10 Wiring Diagrams
J203
28
J403 J401 J604 J601
- +
4 5 6 7 8 9 10 11 12 13 14
J201
1 2 3
209 222 221 220 Alarm 011 013 015 017 019 031 041 051
-
2T1 4T2 6T3 14NO A2 2T1 4T2 6T3 14NO A2
L3 L2 L1 N PE PE PE 109 122 121 120 001 002 024 021 022 010 012 014 016 018 030 040 050
+
gn/ye
PE
4
3
1
gn/ye
PE
3
1
4
5
18
19 22
5
6 6 (4)
23
30 30 26
gn/ge
gn/ge
22
5
5
4
4
1
F6 F6
24
F7 F7
L1 L2 L3 (N) PE 25
15 16 21
17
015 015 019
27
014 014
Analog IN Analog IN
+24V +24V
(GND)
60 of 68 LevelControl Basic 2
10 Wiring Diagrams
J203
J201
1 2 3
209 222 221 220 Alarm 011 013 015 017 019 031 041 051
-
2T1 4T2 6T3 14NO A2 2T1 4T2 6T3 14NO A2
L3 L2 L1 N PE PE PE 109 122 121 120 001 002 024 021 022 010 012 014 016 018 030 040 050
+
PE
4
3
1
PE
3
1
4
5
18
5 19 22
6 6 (4)
23
30 30
26
PE
PE
5
5
4
22
1
F6 F6
24
L1 L2 L3 (N) PE 25
15 16 17 21
015 015 019
014 014 27
Analog IN Analog IN
+24V +24V
(GND)
LevelControl Basic 2 61 of 68
10 Wiring Diagrams
Ama-Porter NE
J203
J201
1 2 3
209 222 221 220 Alarm 011 013 015 017 019 031 041 051
-
2T1 4T2 6T3 14NO A2 2T1 4T2 6T3 14NO A2
L3 L2 L1 N PE PE PE 109 122 121 120 001 002 024 021 022 010 012 014 016 018 030 040 050
+
PE gn/ye
PE gn/ye
PE gn/ye
bu
bu
bn
bk
bu
bn
18
19 22
23
26
29 29 22
gn/ye
gn/ye
bn
bn
bu
bu
24
25
PE gn/ye
bk bu
21
014 014 27
Analog IN Analog IN
+24V +24V
(GND)
62 of 68 LevelControl Basic 2
10 Wiring Diagrams
14 Pneumatic 29 230 V
bk (black)
bu (blue)
bn (brown)
PE = gn/ye (green/yellow)
15 Pump 1
Ama-Porter ND 400V
J203
J201
1 2 3
209 222 221 220 Alarm 011 013 015 017 019 031 041 051
-
2T1 4T2 6T3 14NO A2 2T1 4T2 6T3 14NO A2
L3 L2 L1 N PE PE PE 109 122 121 120 001 002 024 021 022 010 012 014 016 018 030 040 050
+
PE gn/ye
bn
bu
bk
PE gn/ye
bn
bu
bk
18
5 19 22
4 4 (4)
23
30 30
26
W1
U1
V1
W1
U1
V1
PE
PE
22
24
L1 L2 L3 (N) PE
25
15 16 17
21
015 015 019
014 014 27
Analog IN Analog IN
+24V +24V
(GND)
LevelControl Basic 2 63 of 68
10 Wiring Diagrams
14 Pneumatic 30 400 V
U1: bk (black)
V1: bu (blue)
W1: bn (brown)
PE: gn/ye (green/yellow)
15 Pump 1
Amarex N
J203
J201
1 2 3
209 222 221 220 Alarm 011 013 015 017 019 031 041 051
-
2T1 4T2 6T3 14NO A2 2T1 4T2 6T3 14NO A2
L3 L2 L1 N PE PE PE 109 122 121 120 001 002 024 021 022 010 012 014 016 018 030 040 050
+
22
20
21
9
PE
3
1
PE
20
22
21
3
1
18
19 22
5
8 8 (4)
23
30 30 26
21
20
21
20
22
22
PE
PE
9
22
1
24
25
L1 L2 L3 (N) PE
21
15 16 17
015 015 019
014 014 27
Analog IN Analog IN
+24V +24V
(GND)
64 of 68 LevelControl Basic 2
11 EU Declaration of Conformity
11 EU Declaration of Conformity
LevelControl Basic 2
Models BC (Basic Compact) and BS (Basic Switchgear)
Series code range: 2018w01 to 2019w52
▪ is in conformity with the provisions of the following Directives as amended from time to time:
– Electromagnetic Compatibility Directive 2014/30/EU
– Low-voltage Directive 2014/35/EU
Joachim Schullerer
Head of Product Development Pump Systems and Drives
KSB SE & Co. KGaA
Johann-Klein-Straße 9
67227 Frankenthal
LevelControl Basic 2 65 of 68
Index
Index
A P
Alerts and warnings Parameters
Acknowledgement 28 Setting 25
Alerts list
Display 29 R
ATEX mode 29 Rechargeable battery
Deactivating 30 Inserting/replacing 30
C S
Checklist 56 Safety 7
Commissioning 22 Safety awareness 8
Control panel 18 Service interface 21
Shutdown 22
D Storage 9
Dimensions 14
Display 19 T
Disposal 10 Transport 9
Draining
via analog measurement 4 .. 20 mA 45
via digital level switches 35 W
via float switches 32 Warnings 7
via float switches (without hysteresis) 38 Wiring diagrams 59, 60, 61
via pneumatic pressure measurement or bubbler
control 41
E
Electrical data 13
External alarm 54
F
Faults
Causes and remedies 57
Filling
via float switches 48
Filling with analog measurement 4..20mA 51
H
High water alert 19
K
Key to safety symbols/markings 7
M
Manual-0-automatic selector switch 20
Measured value parameters 23
N
Name plate 11
Navigation keys 19
O
Other applicable documents 6
66 of 68 LevelControl Basic 2
(01152996)
4041.80/10-EN