Hycontrol DP600 User manual

Instruction Manual
Seventh revision, February 2022
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
Vibrating Level Switch
DP600
DP630
DP650

DP600/630/650 / Instruction Manual 0222
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Instruction Manual
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 DP600/630/650 SERIES are vibration-type level control
instruments that detect the minimum or maximum level in bins, silos
and hoppers, filled with grained materials (bulk solids). Typical product
applications are plastic granules, all kinds of pellets, corn etc.
IMPORTANT:
The instruments cannot be used for detecting materials which are sticky
and tend to build a deposit on the vibrating rod!
General Notes:
▪Installation and maintenance must be performed by qualified
technical personnel only.
▪DP600/630/650 must be used only in the manner outlined in this
instruction manual.
▪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
▪DP600: standard model, insertion length 157mm
▪DP630: model with tube extension, insertion length max. 1.0m
▪DP650: model with cable extension, insertion length max. 4.0m
Function
The signal from the electronic circuit excites the rod of the instrument to
vibrate at its resonance frequency of approx. 460 Hz. When material
covers the rod of the probe, the vibration stops. This is sensed by the
electronic circuitry which forces its output to switch. When the rod gets
uncovered, the vibration will restart and the output switches back.
Technical Data
General:
Enclosure: Die-cast aluminium (powder coated RAL 2008)
Protection IP66
(IP65 for remote electronics installation)
1 cable gland M16x1.5 (option: 2 cable glands)
Suitable for cable diameters 4.5 to 10 mm
Probe: Stainless steel 1.4301 / AISI 304
Resonance frequency approx. 460 Hz
Extension cable DP650: PU sheathed
Connection: Thread 1”BSPT (EN 10226) or 1”NPT
Time Delay 1 second from stop of vibration
2 to 5 seconds for start of vibration
Indication Relay: red LED on PCB
2-wire: green LED on PCB
Power supply: yellow LED on PCB
(relay version only)
Density of material
to be monitored: min. 20 g / litre
Max. load upon the
end of the rod: 80 N
Max. load on
cable DP650: 200 kg
Max. pressure inside bin: 10 bar
(0.8 … 1.1 bar for models with ATEX or UKEX approval)
Safety: protection class I / installation category III /
pollution degree 2 / altitude max. 2000m
Electronics:
Wide range version with relay output
Power Supply: 20...250V AC/DC
Relay Output: One volt free change over contact (SPDT)
Max. switching voltage: 250V AC
Max. switching current: 5A (NO-contact),
3A (NC-contact)
Max. switching power:1250VA @ cos = 1,
150 Watt for DC
Power Consumption: 3VA
2-Wire DC-Version with 8/16mA current output
Power Supply: 20…30V DC
Current: Max-Alarm FH: 8mA (probe vibrating)
16mA (probe damped)
Min-Alarm FL: 8mA (probe damped)
16mA (probe vibrating)
Note: 2-Wire version is NOT ATEX or UKEX approved.
For 2-Wire models without approval, power supply and signal conversion
can be performed by any suitable DC supply with current sensing capability.
In this case the maximum technical data have to be considered.
Power consumption: ≤0.5W
Max. wire diameter for power supply and output signal: 1.5 mm²
Max. allowed ambient and process temperature range:
Ambient temperature for electronics: -20°C ... + 60°C
Ambient temperatures depend on process temperatures as follows:
Process temperature for standard probe: -20°C ... + 80°C
Process temperature for probe HT: -20°C ... + 150°C
(special model for high temperatures)
Process temperature for probe DP650: -20°C ... + 70°C
CE Conformity
The level switches DP600/630/650 meet the requirements of the
following EU regulations:
▪ EU EMC-directive 2014/30/EU
▪ EU Low Voltage Directive 2014/35/EU
▪ ROHS2 2011/65/EU
UKCA Conformity
The level switches DP600/630/650 meet the requirements of the
following UK regulations:
▪ 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

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Approvals
Dust Ex
The vibration type level switches DP600StEx/ DP630StEx and
DP650StEx 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 models with remote
electronics installation. Approved instruments have the indices “StEx”
and a name plate showing the following data:
Applied standards: EN 60079-0 and EN60079-31.
For ATEX or UKEX approved instruments please also read the
special safety instructions at page 7 of this manual!
Mounting
The following has to be considered when mounting DP600/630/650,
(please refer to the sketch below):
•The switching point depends on the density of the material: for
heavy materials only a few millimetres of the vibrating rod have to
be covered for damping of the vibration. With light materials the
material must cover thevibrating rod completely in order to damp its
vibration.
•The instrument must not bemounted in or near the path of incoming
material. The falling material could damage the probe.
•In order to keep the ambient temperature of the PCB within the
allowed range of -20 to +60°C the housing should be protected from
direct sunlight by installing a sun shield.
•A heat barrier should be installed between the enclosure and the bin
wall if the temperature of the material inside the bin exceeds 60°C.
Alternatively it is possible to use a temperature insulating tube fitted
between the mounting socket and enclosure (see page 5 - Special
Models).
Side mounting or vertical mounting:
•DP600 and DP630 can be mounted on the container either from
the side or vertically from top or bottom. DP650 is for top
mounting only.
•For side mounting it is recommended to screw the unit into the
bin wall with the vibrating rod pointing slightly downwards
(approx. 20°) so that material can more easily flow.
•The unit must not be mounted in or near the path of incoming
material. If this cannot be avoided a protection shield, for
example an angle iron with side length approx. 50mm, must be
installed approx. 150mm over the probe. A protection shield is
also necessary for low level detection in order to protect the
probe against falling material.
•The unit is installed by screwing the mounting socket into the
bin wall by means of a 36 mm open end wrench.
•A suitable sealing (like Teflon tape) must be applied to the
thread.
IMPORTANT:
Do not screw by turning the housing!
Orientation of the cable glands:
The cable glands must always point downwards to prevent moisture
seeping insidethe housing. If the housing is not in thecorrect position
after the probe has been firmly screwed into the bin wall, proceed as
follows:
•Remove the cover of the housing, use a 4mm hexagon socket
screw key, (Allen key)
•Use a 10mm wrench to loosen the mounting nut in the centre of
the enclosure
•Turn the housing into the correct position sothat the cable glands
are pointing downwards
•Tighten the mounting nut, torque 3 to 4 Nm
•Close the cover of the housing (torque 3Nm).
Cable ducts which are not used must be sealed!

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Wiring
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 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).
The cables for power supply and output signal must be connected to the
terminals according to the following sketch:
Wide range version with relay output
Terminals for
power supply:
1 = L
Terminals
for relay:
5 = NC
2 = N
6 = COM
3 = protective earth
7 = NO
4 = protective earth
The probe is connected to the PCB by the three leads of the probe:
terminal probe: 8 = T (red lead), 9 = R (yellow lead), 10 = ┴(black lead)
2-wire-version with current output 8/16mA
This model must be connected to a supply and analysing unit as
follows: T1: 20-30vDC T2: ground
Note: 2-Wire version is NOT ATEX or UKEX approved.
Adjustment
Failsafe high ( FH ) / Failsafe low ( FL ):
Switching Logic: see following sketch.
Failsafe high for high level alarm: jumper in position FH:
The relay is de-energized (position NC, red LED off), when the rod is
covered by material or power has failed. The 2-wire version takes
16mA and the green LED is on.
Failsafe low for low level alarm: jumper in position L:
The relay is de-energized (position NC, red LED off), when the blade
is free, (not covered by material), or power has failed. The 2-wire
version takes 16mA and the green LED is on.
Sensitivity setting:
Selectable by jumper:
Pos. A: use this setting only for light material with densities down
to 20g/l. The sensitivity is 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 rod. As the sensitivity of the
instrument is low at position C, light materials cannot be
detected at this setting!

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Special Models
Special model for high temperatures:
This model 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
ambient temperature of the electronics, (60°C), will not be exceeded due
to thermal conduction via the probe a temperature insulating tube has to
be mounted between probe and enclosure, (see following chapters).
Temperature Insulating Tube (Already assembled):
The tube is fixed onto the mounting socket of the probe by means of a
80mm long mounting nut M6. The enclosure is fixed onto the tube by
means of a washer 50x3 and the mounting nut M6x40. The red O-ring
sealing, (special material Silicon), must be located between the mounting
socket and tube, and the black standard O-Ring must be located between
tube and enclosure. Use torque 3 to 4 Nm for the screwing of the
mounting nuts.
Remote Electronics Installation
If the temperature outside the bin near the bin wall exceeds the max.
allowed ambient temperature of the PCB, (60°C), as an alternative to the
temperature insulating tube the PCB can be installed in a remote
enclosure away from the bin where the temperature is in the allowed
range. Remote electronics installation is also necessary in the case of
heavy vibrations of the bin. In this case the remote enclosure has to be
installed at a place apart 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 which is 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
Contact the distributor who has supplied you with this instrument for
spare parts or contact Hycontrol directly.
Assembling of probe, enclosure and electronics must be done according
to the sketch on the right.
Drawing of the remote electronics installation
The following has to be considered:
▪assembling must be done by qualified personnel only
▪all O-ring sealing must sit in its appropriate position according
to the sketch above
▪apply torque 3 to 4Nm for the mounting nut M6x40
▪apply torque 3Nm for the screw M6x16
▪apply torque 3Nm for the cable gland.
▪care must be taken that special model probes will only be used
together with the appropriate special model electronics.
Maintenance
DP600/630/650 require no maintenance.
For applications with materials that tend to be sticky we recommend
cleaning the vibrating rod of the instrument periodically. If the
instruments are exposed to a corrosive atmosphere they must be
inspected periodically regarding possible corrosion of probe and
enclosure in order to ensure the protection of the instruments.
▪

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Dimensions
DP630
DP650
DP600

0222 DP600/630/650 / Instruction Manual
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Safety Guidelines
Safety guidelines for use of the vibrating level switches DP600StEx / DP630StEx / DP650StEx in the presence of combustible
dust.
General:
The vibrating level switches DP600StEx / DP630StEx / DP650StEx 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.
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 DP600StEx / DP630StEx / DP650StEx is a nameplate showing the following data:
or
or
or
xxxx = Notified or Approved body number for Quality Assurance Notification.
Categories and allowed Zones of the components:
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
e.g:
DP600 StEx with wide range
power supply, standard unit
(no high temp)
e.g:
DP600-REM StEx Remote
electronics with wide range
power supply, standard unit
(no high temp)
e.g:
DP600-HT StEx with wide
range power supply,
high temp
e.g:
DP600-REM-HT StEx
Remote electronics with
wide range power supply,
high temp

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Protection according to EN 60079-0 and EN60079-31:
•protection by dust-tight enclosure IP6X
•limited surface temperatures of the apparatus
Maximum surface temperatures:
Zone
Type
Max. permissible
temperature
Max. surface
temperature at
failure
Heat up
due to
failure
Zone 20
(probe)
DP600/DP630
DP650
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*
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.
*The 35K maximum heat up of
the enclosuresurface 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.