KROHNE OPTISWITCH 5200C User manual

Operating Instructions
OPTISWITCH 5200 C,5250 C
with transistor 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
2.4General safety instructions ................ 5
2.5CE conformity ......................... 5
2.6SIL conformity ......................... 6
2.7Safety information for Ex areas............. 6
3Product description
3.1Configuration.......................... 7
3.2Principle of operation.................... 7
3.3Adjustment ........................... 9
3.4Storage and transport ................... 9
4Mounting
4.1General instructions..................... 10
4.2Mounting information .................... 12
5Connecting to power supply
5.1Preparing the connection ................. 16
5.2Connection procedure ................... 16
5.3Wiring plans,single chamber housing ........ 17
6Set up
6.1General.............................. 20
6.2Adjustment elements .................... 20
6.3Function chart ......................... 21
7Maintenance and fault rectification
7.1Maintenance .......................... 23
7.2Fault rectification ....................... 23
7.3Instrument repair ....................... 24
8Dismounting
8.1Dismounting procedure .................. 25
8.2Disposal ............................. 25
2OPTISWITCH 5200 C,5250 C-with transistor output
Contents
30432-EN-050622

9Functional safety
9.1General.............................. 26
9.2Planning ............................. 27
9.3Setup ............................... 29
9.4Reaction during operation and in case of failure.29
9.5Recurring function test ................... 30
9.6Safety-related characteristics .............. 30
10 Supplement
10.1Technical data......................... 34
10.2Dimensions ........................... 39
10.3Certificates ........................... 41
OPTISWITCH 5200 C,5250 C-with transistor output 3
Contents
30432-EN-050622

1About this document
1.1Function
This operating instructions manual has all the information you
need for quick setup and safe operation of OPTISWITCH 5200
C,5250 C.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 5200 C,5250 C-with transistor output
About this document
30432-EN-050622

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 5200 C,5250 Cis a sensor for level detection.
Detailed information on the application range of OPTISWITCH
5200 C,5250 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 5200 C,5250 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 instal-
lation standards (e.g.the VDE regulations in Germany)as well
as all prevailing safety regulations and accident prevention
rules.
2.5CE conformity
OPTISWITCH 5200 C,5250 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/A1:1998 (class B)
-Susceptibility EN 61326:1997/A1:1998
lNSR:EN 61010-1:1993
OPTISWITCH 5200 C,5250 C-with transistor output 5
For your safety
30432-EN-050622

2.6SIL conformity
OPTISWITCH 5200 C,5250 Cmeets the requirements to the
functional safety acc.to IEC 61508/IEC 61511.Further
information is available in chapter "Functional safety".
2.7Safety information for Ex areas
Please note the Ex-specific safety information for installation
and operation in Ex areas.These safety instructions are part of
the operating instructions manual and come with the Ex-
approved instruments.
6OPTISWITCH 5200 C,5250 C-with transistor output
For your safety
30432-EN-050622

3Product description
3.1Configuration
The scope of delivery encompasses:
lOPTISWITCH 5200 C,5250 Clevel sensor
lDocumentation
-this operating instructions manual
-Ex-specific safety instructions (with Ex versions)and,if
necessary,further certificates
OPTISWITCH 5200 C,5250 Cconsists of the following
components:
lHousing cover
lHousing with electronics
lprocess fitting with tuning fork
1
2
3
Fig.1:OPTISWITCH 5200 C,5250 C-with plastic housing
1Housing cover
2Housing with electronics
3Process fitting
3.2Principle of operation
OPTISWITCH 5200 C,5250 Cis a level sensor with tuning
fork for level detection.
Scope of delivery
Components
Area of application
OPTISWITCH 5200 C,5250 C-with transistor output 7
Product description
30432-EN-050622

It is designed for industrial use in all areas of process
technology and is used in liquids.
Typical applications are overfill and dry run protection.With a
tuning fork of only 40 mm length,OPTISWITCH 5200 C,5250
Ccan be also mounted,e.g.in pipelines from DN 25.The
small tuning fork allows the use in vessels,tanks and pipes.
Thanks to its simple and robust measuring system,OPTI-
SWITCH 5200 C,5250 Cis virtually unaffected by the
chemical and physical properties of the liquid.
It functions also under difficult conditions such as turbulence,
air bubbles,foam generation,buildup,strong external vibration
or changing products.
Fault monitoring
The electronics module of OPTISWITCH 5200 C,5250 C
monitors continuously the following criteria via the frequency
evaluation:
lstrong corrosion or damage of the tuning fork
lno vibration
lline break to the piezo drive
If a fault 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).
OPTISWITCH 5200 C,5250 Cfulfills the requirements of
IEC 61508 and 61511 of SIL2(see Supplement).
The tuning fork is piezoelectrically energised and vibrates at its
mechanical resonance frequency of approx.1200 Hz.The
piezos are fixed mechanically and are hence not subjected to
temperature shock limitations.The frequency changes if the
tuning fork is covered by the medium.This change is detected
by the integrated oscillator and converted into a switching
command.
OPTISWITCH 5200 C,5250 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 power supply is stated in the Technical
data in the Supplement.
Physical principle
Power supply
8OPTISWITCH 5200 C,5250 C-with transistor output
Product description
30432-EN-050622

3.3Adjustment
The switching condition of OPTISWITCH 5200 C,5250 Cwith
plastic housing can be checked when the housing is closed
(LED display). In the basic adjustment,products with a density
>0.7g/cm³(>0.025 lbs/in³)can be detected.The instrument
can be adapted if products with lower density should be
measured.
On the electronics module you will find the following indicating
and adjustment elements:
lLED for indication of the switching status (green/red)
lDIL switch for switching point adaptation
lMode switch to select the switching condition (A/B)
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 ABS.For special versions
PE foam or PE foil is also used.Dispose of the packaging
material via specialised recycling companies.
lStorage and transport temperature see Supplement –
Technical data –Ambient conditions
lRelative humidity 20 …85 %
Packaging
Storage and transport tempe-
rature
OPTISWITCH 5200 C,5250 C-with transistor output 9
Product description
30432-EN-050622

4Mounting
4.1General instructions
In general,OPTISWITCH 5200 C,5250 Ccan be mounted in
any position.The instrument must be mounted in any position.
The instrument must be mounted in such a way that the tuning
fork is at the height of the requested switching point.
The tuning fork has lateral markings (notches), marking the
switching point with vertical mounting.The switching point
refers to water with the basic setting of the sensitivity switch
>=0.7g/cm³(>=0.025 lbs/in³). When mounting OPTISWITCH
5200 C,5250 C,make sure that this marking is at the height of
the requested switching point.Keep in mind that the switching
point of the instrument is shifted if the medium has a density
other than water -water =1.0g/cm³(=0.036 lbs/in³). For
products <0.7g/cm³(<0.025 lbs/in³)and >0.5g/cm³
(>0.018 lbs/in³)the density switch must be set to >=0.5g/cm³.
2
3
14
Fig.2:Vertical mounting
1Switching point approx.13 mm (ca.0.51 in)
2Switching point with lower density
3Switching point with higher density
4Switching point approx.27 mm (approx.1.06 in)
Switching point
10 OPTISWITCH 5200 C,5250 C-with transistor output
Mounting
30432-EN-050622

1
Fig.3:Horizontal mounting
1Switching point
1
2
Fig.4:Horizontal mounting (recommended installation location -particularly for
adhesive products)
1Switching point
2Marking with screwed version on top -with flange versions directed to the
flange holes
Use the recommended cable (see chapter "Connecting to
power supply")and tighten the cable entry.
You can give your OPTISWITCH 5200 C,5250 Cadditional
protection against moisture penetration by leading the con-
nection 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.5:Measures against moisture penetration
Moisture
OPTISWITCH 5200 C,5250 C-with transistor output 11
Mounting
30432-EN-050622

Do not hold OPTISWITCH 5200 C,5250 Con the tuning fork.
Particularly with flange or tube versions,the tuning fork can be
damaged by the instrument weight.Transport enamelled and
ECTFE coated instruments very carefully and avoid touching
the tuning fork.
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.
Warning:
The housing must not be used to screw the instrument in!
Applying tightening force to the housing can damage its
internal mechanical components.
To screw in,use the hexagon above the thread.
4.2Mounting information
OPTISWITCH 5200 C,5250 Chas a defined thread starting
point.This means that every OPTISWITCH 5200 C,5250 Cis
in the same fork position after being screwed in.Remove
therefore the supplied seal from the thread of OPTISWITCH
5200 C,5250 C.This seal is not required when using a welded
socket with O-ring in front.
Keep in mind that this welded socket is not suitable for coated
instrument versions (e.g.enamel).
Screw OPTISWITCH 5200 C,5250 Ccompletely into the
welded socket.The later position can be determined already
before welding.Mark the appropriate position of the welded
socket.Before welding,unscrew OPTISWITCH 5200 C,5250
Cand remove the rubber ring from the welded socket.The
welded socket has a marking (notch). Weld the socket with the
notch facing upward,or in case of pipelines,aligned with the
direction of flow.
Transport
Pressure/Vacuum
Handling
Welding the socket
12 OPTISWITCH 5200 C,5250 C-with transistor output
Mounting
30432-EN-050622

1
Fig.6:Marking on the welded socket
1Marking
In case of horizontal mounting in adhesive and viscous
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
recommended installation position.
With flange versions,the fork is directed to the flange holes.
In case of adhesive and viscous products,the tuning fork
should protrude into the vessel to avoid buildup.Therefore
sockets for flanges and mounting bosses should be avoided
with horizontal mounting.
IfOPTISWITCH 5200 C,5250 Cis mounted in the filling
stream,unwanted switching signals can be generated.Mount
OPTISWITCH 5200 C,5250 Cat a location in the vessel
where no disturbing influence from e.g.filling openings,
agitators,etc.can occur.
This applies particularly to instrument types with long exten-
sion tube.
Adhesive products
Inflowing medium
OPTISWITCH 5200 C,5250 C-with transistor output 13
Mounting
30432-EN-050622

Fig.7:Inflowing medium
If there is movement within the product,the tuning fork of
OPTISWITCH 5200 C,5250 Cshould be mounted in such a
way that the surfaces of the fork are parallel to the product
movement.
Due to agitators,vibrations or similar,the level switch can be
subjected to strong lateral forces.For this reason,do not use
an overly long extension tube for OPTISWITCH 5200 C,5250
C,but check if you can mount an OPTISWITCH 5100 C,
5150 Clevel switch on the side of the vessel in horizontal
position.
Extreme vibrations from the system side,e.g.by agitators or
turbulence in the vessel,e.g.by fluidization can cause the
extension tube of OPTISWITCH 5200 C,5250 Cto vibrate.
This will cause increased stress on the upper weld joint.
Should a longer tube version be necessary,you can provide a
suitable straining or fastening directly above the tuning fork to
fasten the extension tube.
This measure applies particularly to applications in Ex areas
category 1Gor WHG.Make sure that the tube is not bent by
this measure.
Flow
Agitators
14 OPTISWITCH 5200 C,5250 C-with transistor output
Mounting
30432-EN-050622

Fig.8:Lateral straining of OPTISWITCH 5200 C,5250 C
Instruments with enamel coating should be treated very
carefully and shocks should be avoided.Unpack OPTI-
SWITCH 5200 C,5250 Cdirectly before installation.Insert
OPTISWITCH 5200 C,5250 Ccarefully into the vessel
opening and avoid touching any sharp vessel parts.
Enamel coating
OPTISWITCH 5200 C,5250 C-with transistor output 15
Mounting
30432-EN-050622

5Connecting to power supply
5.1Preparing the connection
Always observe the following safety instructions:
lConnect only in the complete absence of line voltage
In hazardous areas you should take note of the appropriate
regulations,conformity and type approval certificates of the
sensors and power supply units.
Connect the power supply acc.to the following diagrams.Take
note of the general installation regulations.As a rule,connect
OPTISWITCH 5200 C,5250 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.InEx applications,the installation
regulations for hazardous areas must be given priority.
The data for power supply are stated in the Technical data in
the Supplement.
OPTISWITCH 5200 C,5250 Cis connected with standard
cable with round wire 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.
In hazardous areas,only use approved cable connections for
OPTISWITCH 5200 C,5250 C.
Take note of the corresponding installation regulations for Ex
applications.
5.2Connection procedure
With Ex instruments the housing cover may be opened only if
no explosive atmosphere is present.
Proceed as follows:
1Unscrew the housing cover
2Loosen compression nut of the cable entry
Note safety instructions
Take note of safety
instructions for Ex
applications
Select power supply
Select connection cable
Select connection
cable for Ex applica-
tions
16 OPTISWITCH 5200 C,5250 C-with transistor output
Connecting to power supply
30432-EN-050622

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
5Open the terminals with a screwdriver
6Insert the wire ends into the open terminals according to
the wiring plan
7Tighten the terminals with a screwdriver
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
10 Screw the housing cover back on
The electrical connection is finished.
5.3Wiring plans,single chamber housing
The following illustrations apply to the non-Ex as well as to the
EEx d version.
1
4
44
2 3
Fig.9:Material versions,single chamber housing
1Plastic (not with EExd)
2Aluminium
3Stainless steel (not with EExd)
4Filter element for pressure compensation (not with EExd)
Housing overview
OPTISWITCH 5200 C,5250 C-with transistor output 17
Connecting to power supply
30432-EN-050622

SW E60T
10-55V DC
1PNP234 1 NPN234
A
B
0,5g/ cm3
0,7g/ cm3
max 400mA
out
1234
+++
3
5
1
2
4
Fig.10:Electronics and connection compartment,single chamber housing
1LED display
2DIL switch for mode adjustment
3DIL switch for switching point adaptation
4Ground terminal
5Terminals
We recommend connecting OPTISWITCH 5200 C,5250 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.
+ -
1234
+-
Fig.11:NPN action
Electronics and connection
compartment
Wiring plan
18 OPTISWITCH 5200 C,5250 C-with transistor output
Connecting to power supply
30432-EN-050622

+ -
1234
+-
Fig.12:PNP action
OPTISWITCH 5200 C,5250 C-with transistor output 19
Connecting to power supply
30432-EN-050622

6Set up
6.1General
The numbers in brackets refer to the following illustrations.
The switching condition of the electronics can be checked with
plastic housing and closed housing cover (LED display). In the
basic adjustment,products with a density >0.7g/cm³
(>0.025 lbs/in³)can be detected.In liquids with lower density,
you must set the switch to >0.5g/cm³(>0.018 lbs/in³).
On the electronics module you will find the following indicating
and adjustment elements:
lLED display (1)
lDIL switch for mode adjustment -A/B(2)
lDIL switch for sensitivity adjustment (3)
Note:
For test purposes,immerse the tuning fork of OPTISWITCH
5200 C,5250 Calways in liquids.Do not test the function of
OPTISWITCH 5200 C,5250 Cwith the hand.This can
damage the sensor.
6.2Adjustment elements
1234
1
2
3
Fig.13:Oscillator SW E60T-Transistor output
1LED display
2DIL switch for mode adjustment
3DIL switch for switching point adaptation
Function/Configuration
20 OPTISWITCH 5200 C,5250 C-with transistor output
Set up
30432-EN-050622