KROHNE OPTISWITCH 3100 C User manual

OPTISWITCH 3100 C Handbook
Vibrating Level Switch
Relay (DPDT)

2
Contents
OPTISWITCH 3100 C • Relay (DPDT)
29953-EN-210702
Contents
1 About this document ............................................................................................................... 4
1.1 Function ........................................................................................................................... 4
1.2 Target group ..................................................................................................................... 4
1.3 Symbols used................................................................................................................... 4
2 For your safety ......................................................................................................................... 5
2.1 Authorised personnel ....................................................................................................... 5
2.2 Appropriate use................................................................................................................ 5
2.3 Warning about incorrect use............................................................................................. 5
2.4 General safety instructions............................................................................................... 5
2.5 Safety label on the instrument .......................................................................................... 6
2.6 EU conformity................................................................................................................... 6
2.7 SIL conformity .................................................................................................................. 6
2.8 Installation and operation in the USA and Canada ........................................................... 6
2.9 Safety instructions for Ex areas........................................................................................ 6
3 Product description ................................................................................................................. 7
3.1 Conguration.................................................................................................................... 7
3.2 Principle of operation........................................................................................................ 7
3.3 Adjustment ....................................................................................................................... 8
3.4 Storage and transport....................................................................................................... 8
4 Mounting................................................................................................................................. 10
4.1 General instructions ....................................................................................................... 10
4.2 Mounting instructions ..................................................................................................... 11
5 Connecting to power supply................................................................................................. 15
5.1 Preparing the connection ............................................................................................... 15
5.2 Connection procedure.................................................................................................... 16
5.3 Wiring plan, single chamber housing.............................................................................. 16
6 Setup ....................................................................................................................................... 18
6.1 General information........................................................................................................ 18
6.2 Adjustment elements...................................................................................................... 18
6.3 Function table................................................................................................................. 19
7 Maintenanceandfaultrectication...................................................................................... 21
7.1 Maintenance .................................................................................................................. 21
7.2 Rectify faults................................................................................................................... 21
7.3 Exchanging the electronics module................................................................................ 22
7.4 How to proceed if a repair is necessary.......................................................................... 23
8 Dismount................................................................................................................................. 24
8.1 Dismounting steps.......................................................................................................... 24
8.2 Disposal ......................................................................................................................... 24
9 Supplement ............................................................................................................................ 25
9.1 Technical data ................................................................................................................ 25
9.2 Dimensions .................................................................................................................... 28
9.3 Trademark ...................................................................................................................... 31

3
Contents
OPTISWITCH 3100 C • Relay (DPDT)
29953-EN-210702
Safety instructions for Ex areas
TakenoteoftheExspecicsafetyinstructionsforExapplications.
These instructions are attached as documents to each instrument
with Ex approval and are part of the operating instructions.
Editing status: 2018-11-22

4
1 About this document
OPTISWITCH 3100 C • Relay (DPDT)
29953-EN-210702
1 About this document
1.1 Function
This instruction provides all the information you need for mounting,
connection and setup as well as important instructions for mainte-
nance,faultrectication,theexchangeofpartsandthesafetyofthe
user. Please read this information before putting the instrument into
operation and keep this manual accessible in the immediate vicinity
of the device.
1.2 Target group
This operating instructions manual is directed to trained personnel.
Thecontentsofthismanualmustbemadeavailabletothequalied
personnel and implemented.
1.3 Symbols used
Information, note, tip: This symbol indicates helpful additional infor-
mation and tips for successful work.
Note: This symbol indicates notes to prevent failures, malfunctions,
damage to devices or plants.
Caution: Non-observance of the information marked with this symbol
may result in personal injury.
Warning: Non-observance of the information marked with this symbol
may result in serious or fatal personal injury.
Danger: Non-observance of the information marked with this symbol
results in serious or fatal personal injury.
Ex applications
This symbol indicates special instructions for Ex applications.
• List
The dot set in front indicates a list with no implied sequence.
1 Sequence of actions
Numbers set in front indicate successive steps in a procedure.
Battery disposal
This symbol indicates special information about the disposal of bat-
teries and accumulators.

5
2 For your safety
OPTISWITCH 3100 C • Relay (DPDT)
29953-EN-210702
2 For your safety
2.1 Authorised personnel
All operations described in this documentation must be carried out
onlybytrained,qualiedpersonnelauthorisedbytheplantoperator.
During work on and with the device, the required personal protective
equipment must always be worn.
2.2 Appropriate use
The OPTISWITCH 3100 C is a sensor for point level detection.
Youcannddetailedinformationabouttheareaofapplicationin
chapter " Product description".
Operational reliability is ensured only if the instrument is properly
usedaccordingtothespecicationsintheoperatinginstructions
manual as well as possible supplementary instructions.
For safety and warranty reasons, any invasive work on the device
beyond that described in the operating instructions manual may be
carried out only by personnel authorised by the manufacturer. Arbi-
traryconversionsormodicationsareexplicitlyforbidden.
2.3 Warning about incorrect use
Inappropriate or incorrect use of this product can give rise to applica-
tion-specichazards,e.g.vesseloverllthroughincorrectmounting
or adjustment. Damage to property and persons or environmental
contamination can result. Also, the protective characteristics of the
instrument can be impaired.
2.4 General safety instructions
This is a state-of-the-art instrument complying with all prevailing
regulations and directives. The instrument must only be operated in a
technicallyawlessandreliablecondition.Theoperatorisresponsi-
ble for the trouble-free operation of the instrument. When measuring
aggressive or corrosive media that can cause a dangerous situation
if the instrument malfunctions, the operator has to implement suitable
measures to make sure the instrument is functioning properly.
The safety instructions in this operating instructions manual, the na-
tional installation standards as well as the valid safety regulations and
accident prevention rules must be observed by the user.
For safety and warranty reasons, any invasive work on the device
beyond that described in the operating instructions manual may be
carried out only by personnel authorised by the manufacturer. Arbi-
traryconversionsormodicationsareexplicitlyforbidden.Forsafety
reasons,onlytheaccessoryspeciedbythemanufacturermustbe
used.
To avoid any danger, the safety approval markings and safety tips on
the device must also be observed.

6
2 For your safety
OPTISWITCH 3100 C • Relay (DPDT)
29953-EN-210702
2.5 Safety label on the instrument
The safety approval markings and safety tips on the device must be
observed.
2.6 EU conformity
ThedevicefullsthelegalrequirementsoftheapplicableEUdirec-
tives.ByaxingtheCEmarking,weconrmtheconformityofthe
instrument with these directives.
The EU conformity declaration can be found on our homepage.
2.7 SIL conformity
OPTISWITCH 3100 C meets the requirements to the functional safety
according to IEC 61508. Further information is available in the Safety
Manual "OPTISWITCH 3XXX".
2.8 Installation and operation in the USA and
Canada
This information is only valid for USA and Canada. Hence the follow-
ing text is only available in the English language.
Installations in the US shall comply with the relevant requirements of
the National Electrical Code (ANSI/NFPA 70).
Installations in Canada shall comply with the relevant requirements of
the Canadian Electrical Code.
2.9 Safety instructions for Ex areas
For applications in explosion-proof areas (Ex), only devices with cor-
respondingExapprovalmaybeused.ObservetheEx-specicsafety
instructions.These are an integral part of the operating instructions
and are enclosed with every device with Ex approval.

7
3 Product description
OPTISWITCH 3100 C • Relay (DPDT)
29953-EN-210702
3 Product description
3.1 Conguration
The scope of delivery encompasses:
• OPTISWITCH 3100 C point level switch
• Documentation
– This operating instructions manual
– Exspecicsafetyinstructions(withExversions),ifnecessary
furthercerticates
The OPTISWITCH 3100 C consists of the components:
• Housing lid
• Housing with electronics
• Processttingwithtuningfork
1
2
3
Fig. 1: OPTISWITCH 3100 C with plastic housing
1 Housing lid
2 Housing with electronics
3 Processtting
Thetypelabelcontainsthemostimportantdataforidenticationand
use of the instrument:
• Article number
• Serial number
• Technical data
• Article numbers, documentation
Inadditiontothetypelabeloutsideontheinstrument,youndthe
serial number also inside the instrument.
3.2 Principle of operation
OPTISWITCH 3100 C is a point level sensor with tuning fork for point
level detection.
It is designed for industrial use in all areas of process technology and
is preferably used for bulk solids.
Typicalapplicationsareoverllanddryrunprotection.Thankstoits
simple and robust measuring system, OPTISWITCH 3100 C is virtu-
allyunaectedbythechemicalandphysicalpropertiesofthebulk
solid.
Scope of delivery
Constituent parts
Type label
Application area

8
3 Product description
OPTISWITCH 3100 C • Relay (DPDT)
29953-EN-210702
It also works when subjected to strong external vibrations or changing
products.
Solid detection in water
If OPTISWITCH 3100 C was ordered for solids detection in water, the
tuning fork is set to the density of water. In air or when immersed in
water (density: 1 g/cm³/0.036 lbs/in), OPTISWITCH 3100 C signals
"uncovered". Only when the vibrating element is also covered with
solids (e.g. sand, sludge, gravel etc.) will the sensor signal "covered".
Function monitoring
The electronics module of OPTISWITCH 3100 C continuously moni-
tors the following criteria:
• Correct vibrating frequency
• Linebreaktothepiezodrive
If one of the stated malfunctions is detected or in case of voltage sup-
ply,theelectronicstakesonadenedswitchingstatus,i.e.therelay
deenergises (safe state).
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 electronics module and
converted into a switching command.
OPTISWITCH 3100 C is a compact instrument, i.e. it can be oper-
ated 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, a pump etc.).
Thedataforpowersupplyarespeciedinchapter"Technical data".
3.3 Adjustment
Ontheelectronicsmoduleyouwillndthefollowingdisplayand
adjustment elements:
• Signal lamp for indication of the switching condition (green/red)
• Potentiometer for adaptation to the product density
• Mode switch for selecting the switching condition (min./max.)
3.4 Storage and transport
Your instrument was protected by packaging during transport. Its
capacity to handle normal loads during transport is assured by a test
based on ISO 4180.
The packaging of standard instruments consists of environment-
friendly, recyclable carton material.The sensing element is additional-
ly protected with a cardboard cover. For special versions, PE foam or
PE foil is also used. Please dispose of the packaging material through
specialised recycling companies.
Functional principle
Voltage supply
Packaging

9
3 Product description
OPTISWITCH 3100 C • Relay (DPDT)
29953-EN-210702
Transport must be carried out in due consideration of the notes on the
transport packaging. Nonobservance of these instructions can cause
damage to the device.
The delivery must be checked for completeness and possible transit
damage immediately at receipt. Ascertained transit damage or con-
cealed defects must be appropriately dealt with.
Up to the time of installation, the packages must be left closed and
stored according to the orientation and storage markings on the
outside.
Unless otherwise indicated, the packages must be stored only under
the following conditions:
• Not in the open
• Dry and dust free
• Not exposed to corrosive media
• Protected against solar radiation
• Avoiding mechanical shock and vibration
• Storage and transport temperature see chapter "Supplement -
Technical data - Ambient conditions"
• Relative humidity 20 … 85 %
With instrument weights of more than 18 kg (39.68 lbs) suitable and
approved equipment must be used for lifting and carrying.
Transport
Transport inspection
Storage
Storage and transport
temperature
Lifting and carrying

10
4 Mounting
OPTISWITCH 3100 C • Relay (DPDT)
29953-EN-210702
4 Mounting
4.1 General instructions
Note:
For safety reasons, the instrument must only be operated within the
permissibleprocessconditions.Youcannddetailedinformationon
the process conditions in chapter " Technical data" of the operating
instructions or on the type label.
Hence make sure before mounting that all parts of the instrument ex-
posed to the process are suitable for the existing process conditions.
These are mainly:
• Active measuring component
• Processtting
• Process seal
Process conditions in particular are:
• Process pressure
• Process temperature
• Chemical properties of the medium
• Abrasionandmechanicalinuences
The instrument is suitable for standard and extended ambient condi-
tions acc. to DIN/EN/IEC/ANSI/ISA/UL/CSA 61010-1. It can be used
indoors as well as outdoors.
In general, OPTISWITCH 3100 C can be installed in any position. The
instrument only has to be mounted in such a way that the vibrating
element is at the height of the desired switching point.
Use the recommended cables (see chapter " Connecting to power
supply") and tighten the cable gland.
You can give your instrument additional protection against moisture
penetration by leading the connection cable downward in front of the
cablegland.Rainandcondensationwatercanthusdraino.This
applies mainly to outdoor mounting as well as installation in areas
where high humidity is expected (e.g. through cleaning processes) or
on cooled or heated vessels.
To maintain the housing protection, make sure that the housing lid is
closed during operation and locked, if necessary.
Process conditions
Suitability for the ambient
conditions
Switching point
Moisture

11
4 Mounting
OPTISWITCH 3100 C • Relay (DPDT)
29953-EN-210702
Fig. 2: Measures against moisture ingress
Do not hold OPTISWITCH 3100 C on the vibrating element. Espe-
ciallywithangeandtubeversions,thesensorcanbedamagedby
the weight of the instrument.
Remove the protective cover just before mounting.
Theprocessttingmustbesealedifthereisgaugeorlowpressure
in the vessel. Before use, check if the sealing material is resistant
against the measured product and the process temperature.
Themax.permissiblepressureisspeciedinchapter"Technical
data" 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.
Warning:
The housing must not be used to screw the instrument in! Applying
tightening force can damage internal parts of the housing.
Use the hexagon above the thread for screwing in.
Metric threads
In the case of instrument housings with metric thread, the cable
glands are screwed in at the factory. They are sealed with plastic
plugs as transport protection.
You have to remove these plugs before electrical connection.
NPT thread
In the case of instrument housings with self-sealing NPT threads, it is
not possible to have the cable entries screwed in at the factory. The
free openings for the cable glands are therefore covered with red dust
protection caps as transport protection.
Prior to setup you have to replace these protective caps with ap-
proved cable glands or close the openings with suitable blind plugs.
4.2 Mounting instructions
The vibrating element should protrude into the vessel to avoid
buildup.Forthatreason,avoidusingmountingbossesforanges
Transport
Pressure/Vacuum
Handling
Cable entries - NPT
thread
Cable glands
Mounting socket

12
4 Mounting
OPTISWITCH 3100 C • Relay (DPDT)
29953-EN-210702
andscrewedttings.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llingstream.
20°
a. b.
Fig. 3: Horizontal installation
a Protective sheet
b Concave protective sheet for abrasive solids
If such an installation location should be necessary, mount a suitable
protective sheet above or in front of the vibrating element, see illustra-
tion "a").
In abrasive solids, mounting according 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 OPTIS-
WITCH3100Chorizontally.However,iftheswitchingpointcanhave
a tolerance of a few centimeters, we recommend mounting OPTIS-
WITCH 3100 C approx. 20° inclined to the vessel bottom to avoid
buildup.
Filling opening
Horizontal mounting

13
4 Mounting
OPTISWITCH 3100 C • Relay (DPDT)
29953-EN-210702
20°
Fig. 4: Horizontal mounting
IfOPTISWITCH3100Cismountedinthellingstream,unwanted
false measurement signals can be generated. For this reason, mount
OPTISWITCH 3100 C at a position in the vessel where no disturbanc-
es,e.g.fromllingopenings,agitators,etc.,canoccur.
To make sure the tuning fork of OPTISWITCH 3100 C generates as
littleresistanceaspossibletoproductow,mountthesensorsothat
the surfaces are parallel to the product movement.
1
2
Fig. 5: Flow orientation of the tuning fork
1 Marking with screwed version
2 Directionofow
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nd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 still
Inowingmedium
Productow
Adhesive products

14
4 Mounting
OPTISWITCH 3100 C • Relay (DPDT)
29953-EN-210702
beturnedbyapprox.halfaturn.Thisissucienttoreachtherecom-
mended installation position.
Inthecaseofangeversions,theforkisalignedwiththeangeholes.
1
Fig. 6: Horizontal installation - marking
1 Marking on top with screwed version
In applications such as grit chambers or settling basins for coarse
sediments, the vibrating element must be protected against damage
withasuitablebae.
Thisbaemustbemanufacturedbyyou.
> 125 mm
(> 5")
> 120 mm
(> 4.7")
Fig.7:Baeforprotectionagainstmechanicaldamage
Baeprotectionagainst
falling rocks

15
5 Connecting to power supply
OPTISWITCH 3100 C • Relay (DPDT)
29953-EN-210702
5 Connecting to power supply
5.1 Preparing the connection
Always keep in mind the following safety instructions:
Warning:
Connect only in the complete absence of line voltage.
• The electrical connection must only be carried out by trained,
qualiedpersonnelauthorisedbytheplantoperator.
• Alwaysswitchopowersupply,beforeconnectingordisconnect-
ing the instrument.
Note:
Install a disconnecting device for the instrument which is easy to
access.The disconnecting device must be marked for the instrument
(IEC/EN 61010).
Inhazardousareasyoumusttakenoteoftherespectiveregulations,
conformityandtypeapprovalcerticatesofthesensorsandpower
supply units.
Connect the voltage supply according to the connection diagrams.
The electronics module with relay output is designed in protection
class I. To maintain this protection class, it is absolutely necessary
that the earth conductor be connected to the inner earth conductor
terminal. Keep the general installation regulations in mind.Take note
ofthecorrespondinginstallationregulationsforhazardousareaswith
Ex applications.
Thedataforpowersupplyarespeciedinchapter"Technical data".
The instrument is connected with standard three-wire cable without
screen. If electromagnetic interference is expected which is above the
test values of EN 61326 for industrial areas, screened cable should
be used.
Make sure that the cable used has the required temperature resist-
anceandresafetyformax.occurringambienttemperature
Use cable with round cross-section. A cable outer diameter of
5…9mm(0.2…0.35in)ensuresthesealeectofthecablegland.
Ifyouareusingcablewithadierentdiameterorcross-section,
exchange the seal or use a suitable cable gland.
Inhazardousareas,useonlyapprovedcableconnectionsforOPTIS-
WITCH 3100 C.
Take note of the corresponding installation regulations for Ex applica-
tions.
Cover all housing openings conforming to standard according to
EN 60079-1.
Note safety instructions
Take note of safety
instructions for Ex
applications
Voltage supply
Connection cable
Connection cable
for Ex applications

16
5 Connecting to power supply
OPTISWITCH 3100 C • Relay (DPDT)
29953-EN-210702
5.2 Connection procedure
With Ex instruments, the housing cover may only be opened if there is
no explosive atmosphere present.
Proceed as follows:
1. Unscrew the housing lid
2. Loosen compression nut of the cable gland and remove blind
plug
3. Remove approx. 10 cm (4 in) of the cable mantle, strip approx.
1 cm (0.4 in) of insulation from the ends of the individual wires
4. Insert the cable into the sensor through the cable entry
5. Lift the opening levers of the terminals with a screwdriver (see
following illustration)
Fig. 8: Connection steps 5 and 6
6. Insert the wire ends into the open terminals according to the wir-
ing plan
7. Press down the opening levers of the terminals, you will hear the
terminal spring closing
8. Check the hold of the wires in the terminals by lightly pulling on
them
9. Tighten the compression nut of the cable entry gland. The seal
ring must completely encircle the cable
10. If necessary, carry out a fresh adjustment
11. Screw the housing lid back on
Theelectricalconnectionisnished.
5.3 Wiring plan, single chamber housing
The following illustrations apply to the non-Ex as well as to the Ex-d
version.

17
5 Connecting to power supply
OPTISWITCH 3100 C • Relay (DPDT)
29953-EN-210702
1
4
44
2 3
Fig. 9: Material versions, single chamber housing
1 Plastic (not with Ex d)
2 Aluminium
3 Stainless steel (not with Ex d)
4 Filter element for pressure compensation (not with Ex d)
We recommend connecting OPTISWITCH 3100 C in such a way that
the switching circuit is open when there is a level signal, line break or
failure (safe state).
The relays are always shown in non-operative condition.
3
2 1
Fig. 10: Wiring plan
1 Relay output
2 Relay output
3 Voltage supply
If inductive loads or stronger currents are switched through, the gold
plating on the relay contact surface will be permanently damaged.
The contact is then no longer suitable for switching low-voltage
circuits.
Inductive loads also result from the connection to a PLC input or
output and/or in combination with long cables. It is imperative that you
take measures to extinguish sparks to protect the relay contact (e.g. Z
diode) or use an electronic version with transistor output.
Housing overview
Wiring plan
Connection to a PLC

18
6 Setup
OPTISWITCH 3100 C • Relay (DPDT)
29953-EN-210702
6 Setup
6.1 General information
Theguresinbracketsrefertothefollowingillustrations.
Ontheelectronicsmoduleyouwillndthefollowingdisplayand
adjustment elements:
• Potentiometer for adjustment of the density range (1)
• DIL switch for mode adjustment - min./max. (2)
• Signal lamp (5)
Note:
As a rule, always set the mode with mode switch (2) before starting
the setup of OPTISWITCH 3100 C. The switching output will change
if you set the mode switch (2) afterwards.This could possibly trigger
other connected instruments or devices.
6.2 Adjustment elements
3
4
5
1
2
Fig. 11: Electronics and connection compartment - relay output
1 Potentiometer for adjustment of the density range
2 DIL switch for mode adjustment
3 Ground terminal
4 Connection terminals
5 Control lamp
With the potentiometer you can adapt the switching point to the solid.
Itisalreadypresetandmustonlybemodiedinspecialcases.
By default, the potentiometer of OPTISWITCH 3100 C is set to the
right stop (> 0.02 g/cm³ or 0.0008 lbs/in³). In case of very light-weight
solids, turn the potentiometer to the left stop (> 0.008 g/cm³ or
0.0003 lbs/in³). OPTISWITCH 3100 C will thus be more sensitive and
can detect light-weight solids more reliably.
Function/Conguration
Electronics and connec-
tion compartment
Adjustment of the density
range (1)

19
6 Setup
OPTISWITCH 3100 C • Relay (DPDT)
29953-EN-210702
For instruments detecting solids in water, these settings are not ap-
plicable.The density range is preset and must not be changed.
With the mode setting (min./max.) you can change the switching
condition of the relay.You can set the required mode according to the
"Function table"(max.-max.detectionoroverowprotection,min.-
min. detection or dry run protection).
We recommend connecting according to the idle current principle
(relaycontactdeenergizeswhentheswitchingpointisreached),
because the relay always takes on the same (safe) state if a failure is
detected.
Control lamp for indication of the switching status
• green=relayenergized
• red=relaydeenergized
• red(ashing)=failure
6.3 Function table
The following table provides an overview of the switching conditions
depending on the set mode and the level.
Level Switching status Control lamp
Mode of operation max.
Overowprotection 53 4
(8)(6) (7)
Relayenergized Green
Mode of operation max.
Overowprotection 53 4
(8)(6) (7)
Relaydeenergized Red
Mode of operation min.
Dry run protection 53 4
(8)(6) (7)
Relayenergized Green
Mode of operation min.
Dry run protection 53 4
(8)(6) (7)
Relaydeenergized Red
Failure of the supply volt-
age
(min./max. mode)
any
53 4
(8)(6) (7)
Relaydeenergized
Mode adjustment (2)
Signal lamp (5)

20
6 Setup
OPTISWITCH 3100 C • Relay (DPDT)
29953-EN-210702
Level Switching status Control lamp
Fault any
53 4
(8)(6) (7)
Relaydeenergized ashesred