KROHNE OPTISWITCH 3000 C User manual

Operating Instructions
OPTISWITCH 3000 C
with two-wire output

Contents
1About this document
1.1Function ............................. 4
1.2Target group .......................... 4
1.3Symbolism used ....................... 4
2For your safety
2.1Authorised personnel .................... 5
2.2Appropriate use........................ 5
2.3Warning about misuse ................... 5
2.4CE conformity ......................... 5
3Product description
3.1Configuration.......................... 6
3.2Principle of operation.................... 6
3.3Operation ............................ 7
3.4Storage and transport ................... 7
4Mounting
4.1General instructions..................... 9
4.2Mounting instructions.................... 10
5Connecting to voltage supply
5.1Preparing the connection ................. 13
5.2Connection steps....................... 13
5.3Wiring plan,single chamber housing......... 14
6Set up
6.1General.............................. 16
6.2Adjustment elements .................... 17
6.3Function chart ......................... 18
7Maintenance and fault rectification
7.1Maintenance .......................... 20
7.2Rectify faults .......................... 20
7.3Exchange the electronics ................. 21
7.4Instrument repair ....................... 22
8Dismounting
8.1Dismounting procedure .................. 23
8.2Disposal ............................. 23
9Supplement
9.1Technical data......................... 24
2OPTISWITCH 3000 C-with two-wire output
Contents
30061-EN-060830

9.2Dimensions ........................... 26
9.3Certificates ........................... 27
Supplementary operating instructions manuals
Information:
OPTISWITCH 3000 Cis available in different versions.
Depending on the selected version,supplementary operating
instructions manuals may also come with the shipment.The
supplementary operating instructions manuals are listed in
section "Product description.
Operating instructions manuals for accessories and
replacement parts
Tip:
To ensure reliable setup and operation of your OPTISWITCH
3000 C,we offer accessories and replacement parts.The
associated documents are:
lOperating instructions manual "Oscillator"
OPTISWITCH 3000 C-with two-wire output 3
Contents
30061-EN-060830

1About this document
1.1Function
This operating instructions manual has all the information you
need for quick setup and safe operation.Please read this
manual before you start setup.
1.2Target group
This operating instructions manual is directed to trained,
qualified personnel.The contents of this manual should be
made available to these personnel and put into practice by
them.
1.3Symbolism used
Information,tip,note
This symbol indicates helpful additional information.
Caution:If this warning is ignored,faults or
malfunctions can result.
Warning:If this warning is ignored,injury to persons and/or
serious damage to the instrument can result.
Danger:If this warning is ignored,serious injury to persons
and/or destruction of the instrument can result.
Ex applications
This symbol indicates special instructions for Ex applications.
lList
The dot set in front indicates a list with no implied sequence.
àAction
This arrow indicates a single action.
1Sequence
Numbers set in front indicate successive steps in a procedure.
4OPTISWITCH 3000 C-with two-wire output
About this document
30061-EN-060830

2For your safety
2.1Authorised personnel
All operations described in this operating instructions manual
must be carried out only by trained specialist personnel
authorised by the operator.For safety and warranty reasons,
any internal work on the instruments must be carried out only
by personnel authorised by the manufacturer.
2.2Appropriate use
OPTISWITCH 3000 Cis a sensor for level detection.
Detailed information on the application range of OPTISWITCH
3000 Cis available in chapter "Product description".
2.3Warning about misuse
Inappropriate or incorrect use of the instrument can give rise to
application-specific hazards,e.g.vessel overfill or damage to
system components through incorrect mounting or adjustment.
2.4General safety instructions
OPTISWITCH 3000 Cis a high-tech instrument requiring the
strict observance of standard regulations and guidelines.The
user must take note of the safety instructions in this operating
instructions manual,the country-specific installation standards
(e.g.the VDE regulations in Germany)as well as all prevailing
safety regulations and accident prevention rules.
2.5CE conformity
OPTISWITCH 3000 Cis in CE conformity with EMC (89/336/
EWG), fulfils NAMUR recommendation NE 21 and is in CE
conformity with LVD (73/23/EWG).
Conformity has been judged according to the following
standards:
lEMC:
-Emission EN 61326:1997 (class B)
-Susceptibility EN 61326:1997/A1:1998
lLVD:EN 61010-1:2001
OPTISWITCH 3000 C-with two-wire output 5
For your safety
30061-EN-060830

3Product description
3.1Configuration
The scope of delivery encompasses:
lOPTISWITCH 3000 Clevel sensor
lDocumentation
-this operating instructions manual
-Supplementary instructions manual "Plug connector for
level sensors"(optional)
OPTISWITCH 3000 Cconsists of the following components:
lHousing cover
lHousing with electronics
lprocess fitting with tuning fork
1
2
3
Fig.1:OPTISWITCH 3000 Cwith plastic housing
1Housing cover
2Housing with electronics
3Process fitting
3.2Principle of operation
OPTISWITCH 3000 Cis a level sensor with tuning fork for level
detection.
It is designed for industrial use in all areas of process
technology and is preferably used for bulk solids.
Typical applications are overfill and dry run protection.Thanks
to its simple and robust measuring system,OPTISWITCH
3000 Cis virtually unaffected by the chemical and physical
properties of the bulk solid.
It functions even when exposed to strong external vibration or
changing products.
Scope of delivery
Components
Area of application
6OPTISWITCH 3000 C-with two-wire output
Product description
30061-EN-060830

Fault monitoring
The electronics of OPTISWITCH 3000 Ccontinuously mon-
itors the following criteria:
lCorrect vibrating frequency
lLine break to the piezo drive
If one of these faults is detected,the electronics signals this via
adefined current to the signal conditioning instrument.The
connection cable to the vibrating element is also monitored.
The tuning fork is piezoelectrically energised and vibrates at its
mechanical resonance frequency of approx.150 Hz.When the
tuning fork is submerged in the product,the vibration
amplitude changes.This change is detected by the integrated
oscillator and converted into a switching command.
Depending on your requirements,OPTISWITCH 3000 Cwith
two-wire electronics can be connected to different signal
conditioning instruments.Compatible signal conditioning in-
struments are listed under "Technical data".
The exact range of the power supply is stated in the "Technical
data"in the "Supplement".
3.3Operation
OPTISWITCH 3000 Ccan detect products with a density
>0.08 g/cm³(>0.003 lbs/in³).
On the electronics module you will find the following indicating
and adjustment elements:
lsignal lamp for indication of the switching condition (green/
red)
lmode switch for selection of the output current
3.4Storage and transport
Your instrument was protected by packaging during transport.
Its capacity to handle normal loads during transport is assured
by a test according to DIN 55439.
The packaging of standard instruments consists of environ-
ment-friendly,recyclable cardboard.In addition,the sensor is
provided with a protective cover of cardboard.For special
versions PE foam or PE foil is also used.Dispose of the
packaging material via specialised recycling companies.
Physical principle
Power supply
Packaging
OPTISWITCH 3000 C-with two-wire output 7
Product description
30061-EN-060830

lStorage and transport temperature see "Supplement -
Technical data -Ambient conditions"
lRelative humidity 20 …85 %
Storage and transport tem-
perature
8OPTISWITCH 3000 C-with two-wire output
Product description
30061-EN-060830

4Mounting
4.1General instructions
In general,OPTISWITCH 3000 Ccan be mounted in any
position.The instrument must be mounted in such a way that
the vibrating element is at the height of the requested switching
point.
Use the recommended cables (see chapter "Connecting to
power supply")and tighten the cable gland.
You can give your OPTISWITCH 3000 Cadditional protection
against moisture penetration by leading the connection cable
downward in front of the cable entry.Rain and condensation
water can thus drain off.This applies mainly to mounting
outdoors,in areas where moisture is expected (e.g.by
cleaning processes)or on cooled or heated vessels.
Fig.2:Measures against moisture penetration
Do not hold OPTISWITCH 3000 Con the vibrating element.
The sensor can be damaged by the weight of the instrument.
Remove the protective cover just before mounting.
The process fitting must be sealed if there is gauge or low
pressure in the vessel.Before use,check if the seal material is
resistant against the measured product and the process
temperature.
The max.permissible pressure is stated in the "Technical
data"in the "Supplement"or on the type label of the sensor.
The vibrating level switch is a measuring instrument and must
be treated accordingly.Bending the vibrating element will
destroy the instrument.
Switching point
Moisture
Transport
Pressure/Vacuum
Handling
OPTISWITCH 3000 C-with two-wire output 9
Mounting
30061-EN-060830

Warning:
The housing must not be used to screw in the instrument!
Applying tightening force on the housing can damage its
internal mechanical parts.
To screw in,use the hexagon above the thread.
4.2Mounting instructions
The vibrating element should protrude into the vessel to avoid
buildup.For that reason,avoid using mounting bosses for
flanges and screwed fittings.This applies particularly to use
with adhesive products.
Mount the instrument in such a way that the tuning fork does
not protrude directly into the filling stream.
20°
a. b.
Fig.3:Horizontal mounting
aConvex mounting
bConcave mounting
If such an installation location should be necessary,mount a
suitable protective sheet above or in front of the vibrating
element -see illustration a.).
In abrasive solids,mounting according to illustration b.has
proven.Aspout forms in the concave protective sheet
preventing wear of the protective sheet.
Socket
Filling opening
10 OPTISWITCH 3000 C-with two-wire output
Mounting
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To achieve a very precise switching point,you can install
OPTISWITCH 3000 Chorizontally.However,if the switching
point can have a tolerance of a few centimeters,we
recommend mounting OPTISWITCH 3000 Capprox.20°
inclined to the vessel bottom to avoid buildup.
20°
a. b.
Fig.4:Horizontal mounting
aProtective sheet
bConcave protective sheet for abrasive solids
IfOPTISWITCH 3000 Cis mounted in the filling stream,
unwanted switching signals may be generated.Mount OPTI-
SWITCH 3000 Cat a location in the vessel where no disturbing
influence from e.g.filling openings,agitators etc.can occur.
To minimise flow resistance caused by the tuning fork,
OPTISWITCH 3000 Cshould be mounted in such a way that
the surfaces of the blades are parallel to the product
movement.
Horizontal mounting
Inflowing medium
Flows
OPTISWITCH 3000 C-with two-wire output 11
Mounting
30061-EN-060830

2
1
Fig.5:Orientation of the tuning fork in case of flow
1Marking with screwed version
2Direction of flow
In case of horizontal mounting in adhesive products,the
surfaces of the tuning fork should be vertical in order to reduce
buildup on the blades.On the screwed version you will find a
marking on the hexagon.With this,you can check the position
of the tuning fork when screwing it in.When the hexagon
touches the seal,the thread can be still turned by approx.half
a turn.This is sufficient to reach the recommended installation
position.
1
Fig.6:Vertical installation -marking
1Marking on top with screwed version
Adhesive products
12 OPTISWITCH 3000 C-with two-wire output
Mounting
30061-EN-060830

5Connecting to voltage supply
5.1Preparing the connection
Generally not the following safety instructions:
lConnect only in the complete absence of line voltage
Connect the power supply according to the following diagrams.
Take note of the general installation regulations.As a rule,
connect OPTISWITCH 3000 Cto vessel ground (PA), or in
case of plastic vessels,to the next ground potential.On the
side of the instrument housing there is a ground terminal
between the cable entries.This connection serves to drain off
electrostatic charges.
The data for power supply are stated in the "Technical data"in
the "Supplement".
OPTISWITCH 3000 Cis connected with standard cable with
round cross section.An outer cable diameter of 5... 9mm
(0.2... 0.35 in)ensures the seal effect of the cable gland.
If cable with a different diameter or wire cross section is used,
exchange the seal or use an appropriate cable connection.
5.2Connection steps
Proceed as follows:
1Unscrew the housing cover
2Loosen compression nut of the cable entry
3Remove approx.10 cm (4in)of the cable mantle,strip
approx.1cm (0.4in)insulation from the ends of the
individual wires
4Insert the cable into the sensor through the cable entry
5Lift the opening levers of the terminals with a screwdriver
(see following illustration)
6Insert the wire ends into the open terminals according to
the wiring plan
7Press the opening lever of the terminals downward,you will
hear the terminal spring closing
8Check the hold of the wires in the terminals by lightly
pulling on them
9Tighten the compression nut of the cable entry,the seal
ring must completely encircle the cable
Note safety instructions
Select power supply
Selecting the connection ca-
ble
OPTISWITCH 3000 C-with two-wire output 13
Connecting to voltage supply
30061-EN-060830

10 Screw the housing cover back on
The electrical connection is hence finished.
Fig.7:Connection steps 5and 6
5.3Wiring plan,single chamber housing
4
1
2
3
Fig.8:Electronics and connection compartment
1DIL switch for mode adjustment
2Ground terminal
3Screwed terminals
4Control lamp
Electronics and connection
compartment
14 OPTISWITCH 3000 C-with two-wire output
Connecting to voltage supply
30061-EN-060830

For connection to a signal conditioning instrument.The sensor
is powered via the connected signal conditioning instrument.
For further information see the "Technical data"in the
"Supplement".
The wiring example is applicable for all suitable signal
conditioning instruments.
If the mode switch of OPTISWITCH 3000 Cis correctly set to
"max.",the control lamp on OPTISWITCH 3000 Clights.
lred -with submerged vibrating element
lgreen -with uncovered vibrating element
Take note of the operating instructions manual of the signal
conditioning instrument.Suitable signal conditioning instru-
ments are listed in the Technical data.
1
Fig.9:Wiring plan
1Voltage supply
Wiring plan
OPTISWITCH 3000 C-with two-wire output 15
Connecting to voltage supply
30061-EN-060830

6Set up
6.1General
The numbers in brackets refer to the following illustrations.
On the electronics module you will find the following indicating
and adjustment elements:
lDIL switch for mode adjustment -min./max.(1)
lSignal lamp (4)
Note:
As a rule,always set the mode before starting the setup of
OPTISWITCH 3000 C.If the instrument is used in conjunction
with a signal conditioning instrument,always set the mode
switch (1)on OPTISWITCH 3000 Cto max.mode.
The mode is selected on the signal conditioning instrument
with the mode switch.
The switching output will change if you set one of the two mode
switches afterwards.This could possibly trigger other con-
nected instruments or devices.
Function/Configuration
16 OPTISWITCH 3000 C-with two-wire output
Set up
30061-EN-060830

6.2Adjustment elements
4
1
2
3
Fig.10:Electronics module -Two-wire output
1DIL switch for mode adjustment
2Ground terminal
3Screwed terminals
4Control lamp
With the mode adjustment (min./max.) you can determine the
output current.
When using a signal conditioning instrument,always set the
mode switch to max.mode.
In this case,you select the requested mode acc.to the
"Function chart"(max.-max.detection or overfill protection,
min.-min.detection or dry run detection)on the signal
conditioning instrument.
When used on a control system,the following values apply:
lMode min.
-Vibrating element uncovered -16 mA±1mA
-Vibrating element covered -8mA±1mA
lMode max.
-Vibrating element uncovered -8mA±1mA
-Vibrating element covered -16 mA±1mA
Control lamp for indication of the switching condition.
lgreen =8mA
lred =16 mA
lred (flashing)=Failure (<2.3mA)
Mode adjustment (1)
Signal lamp (4)
OPTISWITCH 3000 C-with two-wire output 17
Set up
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6.3Function chart
OPTISWITCH 3000 Clevel switch
The following chart provides an overview of the switching
conditions depending on the adjusted mode and level.
Mode on the sensor Level Signal current -Sensor Signal lamp -sensor
max.
Overfill protection
8mA
Green
max.
Overfill protection approx.16 mA
red
min.
Dry run protection approx.8mA
Green
min.
Dry run protection approx.16 mA
red
Fault signal
(min./max.mode)any <2.3mA
flashes red
OPTISWITCH 3000 Clevel switch with signal conditioning
instrument1)
The following chart provides an overview of the switching
conditions depending on the adjusted mode of the signal
conditioning instrument and the level.
Note:
Keep in mind that the mode switch of OPTISWITCH 3000 C
must be always set to "max.".
1)You will find suitable signal conditioning instruments under "Technical data"
18 OPTISWITCH 3000 C-with two-wire output
Set up
30061-EN-060830

Mode on the signal
conditioning instru-
ment
Level Signal current -
Sensor
Signal lamp -sensor Signal lamp -sig-
nal conditioning
instrument
Mode A
Overfill protection approx.8mA
Green
Mode A
Overfill protection approx.16 mA
red
Mode B
Dry run protection approx.16 mA
red
Mode B
Dry run protection approx.8mA
Green
Fault signal
(mode A/B)any <2.3mA
flashes red
OPTISWITCH 3000 C-with two-wire output 19
Set up
30061-EN-060830

7Maintenance and fault rectification
7.1Maintenance
When used as directed in normal operation,OPTISWITCH
3000 Cis completely maintenance free.
7.2Rectify faults
OPTISWITCH 3000 Coffers maximum reliability.Nevertheless
faults can occur during operation.These may be caused by the
following,e.g.:
lSensor
lProcess
lPower supply
lSignal processing
The first measure to be taken is to check the output signal.In
many cases,the causes can be determined this way and the
faults rectified.
?OPTISWITCH 3000 Csignals "covered"when the vibrating
element is not submerged (overfill protection)
?OPTISWITCH 3000 Csignals "uncovered"when the
vibrating element is submerged (dry run protection)
lSupply voltage too low
àCheck the power supply
lElectronics defective
àPress the mode switch (min./max.). If the instrument
then changes the mode,the instrument may be
mechanically damaged.Should the switching function
in the correct mode still be faulty,return the instrument
for repair.
àPush the mode switch.If the instrument then does not
change the mode,the oscillator may be defective.
Exchange the oscillator.
àCheck if there is buildup on the vibrating element,and if
so,remove it.
lUnfavourable installation location
àMount the instrument at a location in the vessel where
no dead zones or mounds can form.
àCheck if the vibrating element is covered by buildup on
the socket.
Causes of malfunction
Fault rectification
Checking the switching signal
20 OPTISWITCH 3000 C-with two-wire output
Maintenance and fault rectification
30061-EN-060830