Hycontrol DP220 User manual

Version 1.1
ADH0222
DIAMOND POINT VIBRATING PROBES
DP220 /DP230 /DP240 /DP250
(DP240 Not available in ATEX / UKEX)
Instruction Manual
Hycontrol Ltd., Larchwood House, Orchard Street,
Redditch, Worcestershire, B98 7DP, U.K.
Tel: + 44 (0)1527 406800 Fax: + 44 (0)1527 406810
E-mail: [email protected] Website: www.hycontrol.com
DP220
DP230
DP240
DP250

Instruction Manual DP220/230/240/250 0222
- 2 -
Process temperature / °C
IMPORTANT:
For safety reasons, and to ensure proper function of these instruments, it
is strongly recommended users carefully read this instruction manual
before installation.
Application
The DIAMOND POINT DP220 / DP230 / DP240 / DP250 are vibration-type
level control instruments that detect theminimum or maximum level inbins,
silos and hoppers, filled with grained or powdered materials (bulk solids).
Typical product applications are plastic granules, all kinds of pellets, flour,
cement, lime powder etc.
IMPORTANT:
The instruments cannot be used for detecting materials which are sticky
and tend to build a deposit on the vibrating blade!
General Notes:
▪Installation and maintenance must be performed by qualified
technical personnel only.
▪The DIAMOND POINT vibrating level sensors must be used only in the
manner outlined in this instruction manual.
▪The DIAMOND POINT vibrating level sensors are sensitive instruments
which need to be handled with care. Never expose these instruments
to mechanical loads and temperatures higher than indicated in the
technical data. Do not make any changes on these instruments.
Models (drawings see page 7)
▪DP220: standard model, insertion length approx. 170 mm
▪DP230: with pipe extension welded, insertion length up to 2 m
▪DP240: with pipe extension screwed, insertion length up to 4m
▪DP250: with cable extension, insertion length up to 20 m.
Function
The signal from the electronic circuit of the DIAMOND POINT excites the
blade of the instrument to vibrate at its resonance frequency of 286 Hz.
When material covers the blade of the probe, the vibration stops. This is
sensed by the electronic circuitry which forces its output to switch. When
the blade gets uncovered, the vibration restarts and the output then
switches back.
Technical Data
General:
Enclosure: Die cast aluminium (powder coated RAL2008)
Protection IP66
(IP65 for remote electronics installation)
Two cable glands M20x1.5
Probe: Stainless steel 1.4301 / AISI 304
Resonance frequency 286 Hz
Extension cable DP250: polyurethane sheathed
Connection: Thread 11/2” EN10226 (BSPT) or 11/2” NPT
Optionally: Tri Clamp DIN 32676 for DP230
Time Delay 1 second from stop of vibration
2 to 5 seconds for start of vibration
Indication LED on PCB (option: externally visible)
Material density: Non-sticky bulk solids, min. 20 grams per litre
(10g/l with special model “extreme sensitivity”)
Safety: Protection class I / installation cat. III
Pollution degree 2 / altitude max. 2000m
Max. pressure inside bin: 10bar
(0.8 to 1.1 bar for models with ATEX or UKEX approval)
Max. load onto extension cable DP250: 200kg
Max. load onto vibrating blade: horizontal: 250N, vertical: 1000N
Electronics:
Wide range with relay output
Power Supply: 22...250V AC/DC with relay output
Relay Output: 2 volt-free change-over contact (DPDT),
Max. AC: 250V-AC, 8A, 2000VA, cos= 1
Max. DC: 8.0A at 24V-DC / 1.5A at 48V-DC
Min. DC: 24V / 100mA
Power consumption: ≤3VA
3-wire DC-Version with transistor output
Power Supply: 24V-DC ±10%
Transistor: Volt free NPN or PNP type (max. 48V DC)
350mA @ 24V-DC, short time max. 1A, max. power
20W, power loss max. 3V, max. leakage current
100µA, short circuit proof
Power consumption: < 1 VA (blocked transistor)
Max. wire diameter for power supply and output signal: 2.5 mm²
Outside diameter range for cables: Ø7 …13mm
Max. allowed ambient and process temperature range:
DP 220/230/240
DP250
HT Probe
Process temp.
-40…+80°C
-40…+70°C
-15…+150°C
Ambient temp.
enclosure
-40…+70°C
-40…+70°C
-15…+70°C
Ambient temp.
encl. ATEX or
UKEX
-20…+60°C*
-20…+60°C
-15…+60°C*
*DP240 is NOT ATEX or UKEX approved
The vibration type level sensors DIAMOND POINT DP220 / DP230 / DP240
and DP250 meet the requirements of the following regulations:
CE-Conformity
▪EU EMC-directive 2014/30/EU
▪EU Low Voltage Directive 2014/35/EU
▪ROHS2 2011/65/EU
UKCA Conformity
▪UK Electro magnetic compatibility Regulations SI 2016 No. 1091
▪UK Electrical Equipment (Safety) regulations SI 2016 No. 1101
▪Restriction of the Use of Certain Hazardous Substances in Electrical
and Electronic Equipment Regulations SI 2012 No. 3032 (as
amended)
The following standards are applied:
▪EN 61326-1
▪EN 61010 -1
▪EN 50581
Ambient temp. / °C
DP220/230/240
DP250
Special model HT
with temp. insulating tube

0222 Instruction Manual DP220/230/240/250
- 3 -
Approvals
Dust-Ex: The vibration type level sensors DIAMOND POINT DP220StEx /
DP230StEx and DP250StEx can be used in the presence of combustible
dust according to ATEX directive 2014/34/EU or UKEX SI 2016 No. 1107
(as amended): equipment group II, category 1/2 D or 1/3 D for remote
electronics installation.
Approved instruments have the indices “StEx”and a nameplate with the
following data:
Applied standards: EN 60079-0 and EN 60079-31.
Note: - DP240 is NOT ATEX or UKEX approved.
For ATEX or UKEX approved instruments please also read the special
safety instructions at page 8 of this manual!
Assembling
IMPORTANT:
For protection IP66 it is essential to assemble the instruments according
to the followingsketch. It is very important to watch the appropriate location
of the sealing and to apply the correct torques.
Assembling of tube extension DP240
The DP240 is usually supplied in parts: probe, enclosure with electronics,
extension cable and mounting socket. The extension tube is normally
supplied fully assembled. See page 7 for DP240 drawing.
Mounting
The LEVELSWITCH is installed by screwing the mounting socket of the
instrument into the bin wall by means of a 50 mm open end wrench.
A suitable sealing, (e.g. Teflon tape), must be applied onto the thread.
!!! Do not screw in by turning the housing !!!
Please also consider the following when mounting the LEVELSWITCH:
Switching point:
The switching point of the LEVELSWITCH depends on the density of the
material: for heavy materials like sand only a few millimetres of the
vibrating blade have to be covered for dampingthe vibration. For very light
materials like styrofoam the material must cover the vibrating blade
completely in order to damp its vibration.
Vibration of the silo:
In case of heavy vibration of the silo wall it is recommended to install the
electronics of the unit at a place where no vibrations are present, see
section “Special models”on pages 5 and 6.
Side mounting:
When the probeis inserted into the bin from the side, it must be turned until
the blade is vertically oriented, so that material can flow freely over the
blade and does not rest on it causing false alarm. Alignment of the blade
is verified by the two marks in the mounting socket. These will be facing up
and down when the orientation of the blade is correct.
(See diagram on following page).

Instruction Manual DP220/230/240/250 0222
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Orientation of the cable glands:
The cable glands must always point downwards to prevent moisture
seeping inside the housing. If the housing is not in the correct positionafter
the probe has been firmly screwed into the bin wall, minor corrections can
be made by turning the housing by hand (it is normally very tight).
Wiring
Wiring is made according to the following sketch.
It is very important to consider the following safety guidelines!
Safety Guidelines:
▪The instruments must be used only at fixed installation of the cables
for supply voltage and output signal.
▪Wiring of these instruments must only be performed by qualified
technical personnel.
▪Before opening the cover and start of wiring make sure that power
supply on all wires has been switched off.
▪According to EN 61010-1 a main switch for this instrument has to be
installed nearby the instrument with which power supply for this
instrument and its output can be switched off. This switch must be
marked as main switch of the instrument.
▪For power supplies 50V a protective earth has to be connected to
the terminal on the enclosure.
▪If power supply and relay signal do not have the same source the
connecting wires of the power supply have to be separated from the
connecting wires of the relay by means of wire fasteners in order to
prevent the connecting wires of the power supply from touching the
output terminals and vice versa, (which might be possible in case of
an error, e.g. a broken wire).
IMPORTANT:
The cable glands can be used for cables with outside diameter 7…13mm.
In order to ensure IP rating IP66 cables outside diameter must fall within
this range.
Wide range power supply with relay output DPDT
24V-DC with transistor output
24V-DC with transistor output
Depending on the wiring the transistor output can be either PNP or NPN
type, see sketch. The max. switching power of 20W and the max. current
of 350mA have to be considered.

0222 Instruction Manual DP220/230/240/250
- 5 -
Probe Connection:
DP240 assembly or replacements.
The three wires of the probe get connected to the PCB via spring cage
clamps: push the button of the clamp by means of a small screw driver
and insert the wire end sleeve into the clamp, then release the button.
T = red
┴= black = ground
R = yellow or red
If the probe comes with two red wires these are interchangeable.
Adjustment
Sensitivity:
Selectable by jumper
Pos. A: Use this setting only for very light materials with densities down
to 20g/l, the sensitivity is very high at this setting.
Pos. B: Standard setting, sufficient for most materials.
Pos. C: For heavy materials with high densities which may form a
deposit on the vibrating blade. As the sensitivity of the
instrument is low at position C, very light material cannot be
detected at this setting!
Failsafe high (FH) / Failsafe low (FL):
Switching Logic: see following sketch.
Failsafe high: jumper in position FH:
The relay is de-energized or transistor blocked when the blade is covered
by material (dependent on model).
Failsafe low: jumper in position FL:
The relay is de-energized or transistor blocked when the blade is free (not
covered by material) (dependent on model).
Output signals alarm as well at power failure.
If power fails the LED is off.
Ground Level Test Facility (GLTF):
Ground level test is to be performed when probe is vibrating:
When the contact of the GLTF terminals gets closed, the vibration stops
and the output switches accordingly. Reopening of the test contact allows
the probe to restart its vibration and the output signal switches back. For
installation use a standard pushbutton and a two wire shielded cable,
connect both wires to the GLTF terminals. Connect the screen of the
shielded cable to ground (right clamp). The pushbutton can be installed
up to 500m away from the electronics but the resistance of the cable
should not exceed 100 Ohms /km.
Special Models
Special model for high temperatures:
Available for DP220, DP230 and DP240. These models can be used for
process temperatures up to 150°C.
Important: the instruments appear similar to the standard instruments,
therefore they are marked with labels “Special Model HT”and the serial
numbers of probes and electronics have the indices “-HT”. Special model
probes must only be used together with the appropriate special
model electronics and vice versa! In order to ensure that the max.
ambient temperature of the electronics, (70C°, resp. 60°C for ATEX or
UKEX models), will not be exceeded due to thermal conduction via the
probe a temperature insulating tube has to be mounted between probe and
enclosure or the electronics has to be installed in a remote enclosure (see
page 6).

Instruction Manual DP220/230/240/250 0222
- 6 -
Temperature Insulating Tube:
Already assembled.
Mounted between HT-probe and enclosure in order to avoid heat-up of the
electronics by high process temperatures. The tube is fixed onto the mounting
socket of the probe by means of an 80mm long mounting nut M6. The
enclosure is fixed onto the tube by means of a washer 50x3 and a screw
M6x12. The green O-ring sealings, (special material Viton), can withstand high
temperatures up to 150°C. Use torque 3Nm for the screwing of mounting nut
and screw M6x12.
Special Model “Extreme Sensitivity”
This special model is for applications where extremely light material has to
be detected. It works for materials with bulk densities down to 10 grams
per litre, driven by special electronics. This model also has three sensitivity
settings ABC but even Pos. C is more sensitive than Pos. A of the standard
model.
Remote Electronics Installation
For ATEX or UKEX models refer to Ex safety guidelines on pages 9 & 10.
The drawing shows a remote electronics installation of the DP220. Remote
electronics installation is also possible for DP230, DP240 and DP250. If
the temperature outside the bin near the bin wall exceeds the maximum
ambient temperature of the PCB, (70°C, resp. 60°C for models with ATEX
or UKEX approval), it is necessary to install the PCB in a remote enclosure
away from the bin where the temperature is in the allowed range or to use
the temperature insulating tube. Remote electronics installation is also
necessary in case of heavy vibrations of the bin. In this case the remote
enclosure has to be installed in a place away from the vibrations.
PCB and probe are connected by a shielded cable via the terminal PCB
which is located inside the enclosure, fixed on top of the mounting socket
of the probe. A metal hose, screwed between the remote enclosure and
the enclosure that contains the terminal PCB, protects the cable. The
remote enclosure can be installed by means of the mounting plate. Cable
and metal hose can withstand temperatures up to 80°C. In order to achieve
IP65 protection both connections of the metal hose have to be tightened
firmly (torque 3 to 4 Nm).
Spare Parts
The following spare parts are available:
▪vibrating probe
▪electronics
▪enclosure
▪mounting socket (for DP240 only)
Contact the distributor who has supplied you with this instrument for
spare parts or contact Hycontrol directly.
Spare parts must be mounted by qualified personnel only according to the
descriptions in this instruction manual. Care must be taken that special
model probes will only be used together with the appropriate special model
electronics.
Maintenance
The DIAMOND POINT vibrating type level switches require no maintenance.
For applications with materials that tend to be sticky we recommend
cleaning the vibrating blade of the instrument periodically. If the
instruments are exposed to corrosive atmosphere they must be inspected
periodically regarding corrosion of probe and enclosure in order to ensure
the protection of the instruments.

0222 Instruction Manual DP220/230/240/250
- 7 -
Dimensions
DP220
DP230
DP250
DP240

Instruction Manual DP220/230/240/250 0222
- 8 -
DP230 HT

0222 Instruction Manual DP220/230/240/250
- 9 -
Safety Guidelines
Safety guidelines for use of the vibrating level switches DP220StEx / DP230StEx / DP250StEx in the
presence of combustible dust.
General:
The vibrating level switches DP220StEx / DP230StEx / DP250StEx can be used in the presence of combustible dust according to ATEX
directive 2014/34/EU or UKEX SI 2016 No. 1107 (as amended): equipment group II, category 1/2 D or 1/3 D for remote electronics
installation.
Note: - DP240 is NOT ATEX or UKEX approved.
Marking of approved instruments according to ATEX directive 2014/34/EU or UKEX SI 2016 No. 1107 (as amended):
On the enclosure of the vibrating level switches DP220StEx / DP230StEx / DP250StEx is a nameplate showing the following data:
e.g:
DP220 StEx with wide range
power supply, standard unit,
(no high temp)
or
e.g:
DP220-HT StEx with wide range
power supply, high temperature unit
or
e.g:
DP220-REM StEx
Remote electronics with wide
range power supply, standard unit,
(no high temp)
xxxx = Notified or Approved body number for Quality Assurance Notification.
Categories and allowed Zones of the components:
Protection according to EN 60079-0 and EN60079-31:
▪protection by dust-tight enclosure IP6X
▪limited surface temperatures of the apparatus
Component
Category
EPL
Equipment Protection Level
Can be used in Zone
Probe
1 D
Da
20, 21 or 22
Enclosure with PCB
2 D
Db
21 or 22
Remote Electronics Installation
3 D
Dc
22

Instruction Manual DP220/230/240/250 0222
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Maximum surface temperatures:
*35K maximum heat up of the enclosure
surface results in a 25K heat up of the
electronics at failure and an additional 10K due
to heat conduction via the probe in cases where
the process temperature is higher than 60°C.
Special guidelines for installation, set up and maintenance of apparatus in the presence of combustible dust:
▪Installation, set up and maintenance must be performed in conjunction with the instruction manual and by qualified technical personnel only.
▪Local governing regulations and standards must be followed.
▪The enclosure must only be opened when power supply on all wires has been switched off.
▪Before opening the enclosure dust deposits must be removed and dust clouds must be avoided.
▪In order to maintain the protection by dust-tight enclosure it is essential that assembling of the instruments must be performed according to the
descriptions in the instruction manual. Special care must be taken that all sealings and sealing planes are not to be damaged and that all sealings
sit in its appropriate position. All screws must be fastened by applying the torques according to the instruction manual.
Zone
Type
Max. permissible
temperature
Max. surface
temperature at
failure
Heat up
due to
failure
Zone 20
(probe)
DP220/DP230
DP250
High temperature version
80°C
70°C
150°C
80°C
70°C
150°C
0 K
0 K
0 K
Zone 21/22
Enclosure with PCB
60°C
95°C
+35 K*