KROHNE OPTISWITCH 3000 C User manual

Operating Instructions
OPTISWITCH 3000 C
with transistor output

Contents
1About this document
1.1Function ............................. 5
1.2Target group .......................... 5
1.3Symbolism used ....................... 5
2For your safety
2.1Authorised personnel .................... 6
2.2Appropriate use........................ 6
2.3Warning about misuse ................... 6
2.4General safety instructions ................ 6
2.5CE conformity ......................... 6
3Product description
3.1Configuration.......................... 7
3.2Principle of operation .................... 7
3.3Adjustment ........................... 8
3.4Storage and transport ................... 8
4Mounting
4.1General instructions ..................... 10
4.2Mounting information .................... 11
5Connecting to power supply
5.1Preparing the connection ................. 14
5.2Connection procedure ................... 14
5.3Wiring plans,signal chamber housing ........ 16
6Setup
6.1General.............................. 18
6.2Adjustment elements .................... 18
6.3Function chart ......................... 19
7Maintenance and fault rectification
7.1Maintenance .......................... 21
7.2Fault rectification ....................... 21
7.3Exchanging the electronics................ 22
7.4Instrument repair ....................... 23
8Dismounting
8.1Dismounting steps ...................... 24
8.2Disposal ............................. 24
2OPTISWITCH 3000 C-with transistor output
Contents
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9Supplement
9.1Technical data......................... 25
9.2Dimensions ........................... 27
9.3Certificates ........................... 28
Supplementary operating instructions manuals
Information:
OPTISWITCH 3000 Cis available in different versions.
Depending on the selected version,supplementary operating
instructions manuals will also be included in the delivery.The
supplementary operating instructions manuals are listed in
section "Product description".
Operating instructions manuals for accessories and
replacement parts
Tip:
To ensure reliable use and operation of your OPTISWITCH
3000 Cwe offer accessories and replacement parts.The
corresponding operating instructions manuals are:
lOperating instructions manual "Oscillator"
OPTISWITCH 3000 C-with transistor output 3
Contents
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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
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,warning,danger
This symbol informs you of a dangerous situation that could
occur.Ignoring this cautionary note can impair the person and/
or the instrument.
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 transistor output
About this document
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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 the NAMUR recommendation NE 21 and is in CE
conformity with NSR (73/23/EWG).
Conformity has been judged acc.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 transistor output 5
For your safety
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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 C-with 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 solid.
It functions even when exposed to strong external vibration or
changing products.
Scope of delivery
Components
Area of application
6OPTISWITCH 3000 C-with transistor output
Product description
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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 or in case the power supply
fails,the electronics takes on a defined switching condition,i.e.
the output transistor blocks (safe condition).
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.
OPTISWITCH 3000 Cis a compact instrument,i.e.it can be
operated without external evaluation system.The integrated
electronics evaluates the level signal and outputs a switching
signal.With this switching signal,a connected device can be
operated directly (e.g.a warning system,aPLC,a pump etc.).
The exact range of the voltage supply is specified in the
"Technical data"in the "Supplement".
3.3Adjustment
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 acc.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
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Product description
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lStorage and transport temperature see "Supplement -
Technical data -Ambient conditions"
lRelative humidity 20 …85 %
Storage and transport tem-
perature
8OPTISWITCH 3000 C-with transistor output
Product description
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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 cable (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 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 transistor output 9
Mounting
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Warning:
The housing must not be used to screw the instrument in!
Applying tightening force on the housing can damage its
internal mechanical parts.
To screw in,use the hexagon above the thread.
4.2Mounting information
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.
Install the instrument in such a way that the tuning fork does
not protrude directly into the filling stream.Should such an
installation location be necessary,mount a suitable baffle
above or in front of the tuning fork.
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 acc.to illustration b.has proven.A
spout forms in the concave protective sheet preventing wear of
the protective sheet.
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.
Socket
Filling opening
Horizontal installation
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Mounting
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20°
a. b.
Fig.3:Horizontal installation
aProtective sheet
bConcave protective sheet for abrasive solids
IfOPTISWITCH 3000 Cis mounted in the filling stream,
unwanted switching signals can 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 fork are parallel to the product movement.
2
1
Fig.4:Orientation of the tuning fork in case of flow
1Marking with screwed version
2Direction of flow
Inflowing material
Flow
OPTISWITCH 3000 C-with transistor output 11
Mounting
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In case of horizontal mounting in adhesive products,the
surfaces of the tuning fork should be vertical in order to reduce
buildup on the tuning fork.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 recom-
mended installation position.
1
Fig.5:Vertical installation -marking
1Marking on top with screwed version
Adhesive products
12 OPTISWITCH 3000 C-with transistor output
Mounting
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5Connecting to power supply
5.1Preparing the connection
Always observe the following safety instructions:
lConnect only in the complete absence of line voltage
Connect the power supply acc.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 offelectrostatic
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 entry.
If cable with a different diameter or wire cross section is used,
exchange the seal or use an appropriate cable connection.
5.2Connection procedure
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 down the opening levers of the terminals,you will
hear the terminal spring closing
8Check the hold of the wires in the terminals by lightly
pulling on them
Note safety instructions
Select power supply
Select connection cable
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Connecting to power supply
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9Tighten the compression nut of the cable entry,the seal
ring must completely encircle the cable
10 Screw the housing cover back on
The electrical connection is finished.
Fig.6:Connection steps 5and 6
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Connecting to power supply
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5.3Wiring plans,signal chamber housing
2
3
4
1
Fig.7:Electronics and connection compartment
1DIL switch for mode adjustment
2Ground terminal
3Terminals
4Control lamp
We recommend connecting OPTISWITCH 3000 Cin such a
way that the switching circuit is open when there is a level
signal,line break or failure (safe condition).
The instrument is used to control relays,contactors,magnet
valves,warning lights,horns as well as PLC inputs.
Electronics and connection
compartment
Wiring plan
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Connecting to power supply
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1
Fig.8:Wiring plan
+ -
+-
Fig.9:NPN action
+-
+ -
Fig.10:PNP action
16 OPTISWITCH 3000 C-with transistor output
Connecting to power supply
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6Setup
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 with the mode switch (1)before
starting setup OPTISWITCH 3000 C.The switching output will
change if you set the mode switch (1)afterwards.This could
possibly trigger other connected instruments or devices.
6.2Adjustment elements
2
3
4
1
Fig.11:Oscillator -Transistor output
1DIL switch for mode adjustment
2Ground terminal
3Terminals
4Control lamp
With the mode adjustment (min./max.) you can change the
switching condition of the transistor output.You can set the
required mode acc.to the "Function chart"(max.-max.
Function/Configuration
Mode adjustment (1)
OPTISWITCH 3000 C-with transistor output 17
Setup
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detection or overfill protection,min.-min.detection or dry run
protection).
We recommend connecting acc.to the quiescent current
principle (transistor blocks when the switching point is
reached)because the transistor output takes on the same
(safe)condition if a failure is detected.
Control lamp for indication of the switching condition.
lgreen =output conducts
lred =output blocks
lred (flashing)=failure
6.3Function chart
The following chart provides an overview of the switching
conditions depending on the adjusted mode and level.
Level Switching sta-
tus
Control lamp
max.mode
Overfill protection transistor con-
ducts
Green
max.mode
Overfill protection transistor blocks
red
min.mode
Dry run protection transistor con-
ducts
Green
min.mode
Dry run protection transistor blocks
red
Failure of the
supply voltage
(min./max.mode)
any transistor blocks
Signal lamp (4)
18 OPTISWITCH 3000 C-with transistor output
Setup
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Level Switching sta-
tus
Control lamp
Failure any transistor blocks
flashes red
OPTISWITCH 3000 C-with transistor output 19
Setup
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7Maintenance and fault rectification
7.1Maintenance
When used as directed in normal operation,OPTISWITCH
3000 Cis completely maintenance-free.
7.2Fault rectification
?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
àPush 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.
lWrong mode selected
àSet the correct mode on the mode switch (max:overfill
protection;min:dry run protection). Wiring should be
carried out acc.to the quiescent current principle.
Checking the switching signal
20 OPTISWITCH 3000 C-with transistor output
Maintenance and fault rectification
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