KROHNE OPTISWITCH 3100 C User manual

Operating Instructions
OPTISWITCH 3100 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
2.4CE conformity ......................... 5
2.5SIL conformity ......................... 6
2.6Safety instructions for Ex areas ............ 6
3Product description
3.1Configuration.......................... 7
3.2Principle of operation.................... 7
3.3Operation ............................ 8
3.4Storage and transport ................... 9
4Mounting
4.1General instructions..................... 10
4.2Mounting instructions.................... 11
5Connecting to voltage supply
5.1Preparing the connection ................. 15
5.2Connection steps....................... 15
5.3Wiring plan,single chamber housing......... 16
6Set up
6.1General.............................. 19
6.2Adjustment elements .................... 19
6.3Function chart ......................... 20
7Maintenance and fault rectification
7.1Maintenance .......................... 22
7.2Rectify faults .......................... 22
7.3Exchange the electronics ................. 23
7.4Instrument repair ....................... 24
8Dismounting
8.1Dismounting procedure .................. 25
8.2Disposal ............................. 25
2OPTISWITCH 3100 C-with transistor output
Contents
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9Supplement
9.1Technical data......................... 26
9.2Dimensions ........................... 29
Supplementary operating instructions manuals
Information:
OPTISWITCH 3100 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
3100 C,we offer accessories and replacement parts.The
associated documents are:
lOperating instructions manual "Oscillator"
OPTISWITCH 3100 C-with transistor output 3
Contents
29954-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 3100 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 3100 Cis a sensor for level detection.
Detailed information on the application range of OPTISWITCH
3100 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 3100 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 3100 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 3100 C-with transistor output 5
For your safety
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2.6SIL conformity
OPTISWITCH 3100 Cfulfills the requirements of functional
safety according to IEC 61508/IEC 61511.You can find further
information in the supplementary instructions manual "Safety
Manual -Functional safety (SIL)OPTISWITCH 3XXX".
2.7Safety instructions for Exareas
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 3100 C-with transistor output
For your safety
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3Product description
3.1Configuration
The scope of delivery encompasses:
lOPTISWITCH 3100 Clevel sensor
lDocumentation
-this operating instructions manual
-Supplementary instructions manual "Plug connector for
level sensors"(optional)
-Ex specific safety instructions (with Ex versions), if
necessary further certificates
OPTISWITCH 3100 Cconsists of the following components:
lHousing cover
lHousing with electronics
lprocess fitting with tuning fork
1
2
3
Fig.1:OPTISWITCH 3100 Cwith plastic housing
1Housing cover
2Housing with electronics
3Process fitting
3.2Principle of operation
OPTISWITCH 3100 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
3100 Cis virtually unaffected by the chemical and physical
properties of the bulk solid.
Scope of delivery
Components
Area of application
OPTISWITCH 3100 C-with transistor output 7
Product description
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It functions even when exposed to strong external vibration or
changing products.
Solid detection in water
IfOPTISWITCH 3100 Cwas ordered for detection of solids in
water,the tuning fork is adjusted to the density of water.In the
air or when covered by water (density:1g/cm³/0.036 lbs/in)
OPTISWITCH 3100 Csignals "uncovered".Only if the
vibrating element is also covered with solids (e.g.sand,
sludge,gravel etc.) will the sensor signal "covered".
Fault monitoring
The electronics of OPTISWITCH 3100 Ccontinuously mon-
itors the following criteria:
lCorrect vibrating frequency
lLine break to the piezo drive
If one of the stated malfunction is detected or in case of power
failure,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 3100 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
directly activated (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".
3.3Operation
With the factory setting,products with a density of >0.02 g/cm³
(>0.0008 lbs/in³)can be measured.The instrument can also
be adapted to products with lower density >0.008 g/cm³
(>0.0003 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)
lpotentiometer for adaptation to the product density
Physical principle
Power supply
8OPTISWITCH 3100 C-with transistor output
Product description
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lMode switch for selecting the switching condition (min./
max.)
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.
lStorage and transport temperature see "Supplement -
Technical data -Ambient conditions"
lRelative humidity 20 …85 %
Packaging
Storage and transport tem-
perature
OPTISWITCH 3100 C-with transistor output 9
Product description
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4Mounting
4.1General instructions
In general,OPTISWITCH 3100 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 3100 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 3100 Con the vibrating element.
Especially with flange and tube versions,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.
Switching point
Moisture
Transport
Pressure/Vacuum
10 OPTISWITCH 3100 C-with transistor output
Mounting
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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 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.).
Handling
Socket
Filling opening
OPTISWITCH 3100 C-with transistor output 11
Mounting
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In abrasive solids,mounting according to illustration b.has
proven.Aspout forms in the concave protective sheet
preventing wear of the protective sheet.
To achieve a very precise switching point,you can install
OPTISWITCH 3100 Chorizontally.However,if the switching
point can have a tolerance of a few centimeters,we
recommend mounting OPTISWITCH 3100 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 3100 Cis mounted in the filling stream,
unwanted switching signals may be generated.Mount OPTI-
SWITCH 3100 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 3100 Cshould be mounted in such a way that
the surfaces of the blades are parallel to the product
movement.
Horizontal mounting
Inflowing medium
Flows
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Mounting
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1
2
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.
With flange versions,the fork is directed to the flange holes.
1
Fig.6:Vertical installation -marking
1Marking 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 baffle.
This baffle must be manufactured by you.
Adhesive products
Baffle protection against fall-
ing rocks
OPTISWITCH 3100 C-with transistor output 13
Mounting
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>125
Fig.7:Baffle protection against damages
14 OPTISWITCH 3100 C-with transistor output
Mounting
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5Connecting to voltage supply
5.1Preparing the connection
Generally not 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 according to the following diagrams.
Take note of the general installation regulations.As a rule,
connect OPTISWITCH 3100 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 3100 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.
In hazardous areas,only use approved cable connections for
OPTISWITCH 3100 C.
Take note of the corresponding installation regulations for Ex
applications.
5.2Connection steps
With Ex instruments,the housing cover may only be opened if
there is no explosive atmosphere 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
Selecting the connection ca-
ble
Select connection
cable for Ex applica-
tions
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Connecting to voltage supply
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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
10 If necessary,carry out a fresh adjustment
11 Screw the housing cover back on
The electrical connection is hence finished.
Fig.8:Connection steps 5and 6
5.3Wiring plan,single chamber housing
The following illustrations apply to the non-Ex as well as to the
EEx d version.
16 OPTISWITCH 3100 C-with transistor output
Connecting to voltage supply
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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)
3
4
5
1
2
Fig.10:Electronics and connection compartment
1Potentiometer for switching point adaptation (covered)
2DIL switch for mode adjustment
3Ground terminal
4Screwed terminals
5Control lamp
We recommend connecting OPTISWITCH 3100 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.
Housing overview
Electronics and connection
compartment
Wiring plan
OPTISWITCH 3100 C-with transistor output 17
Connecting to voltage supply
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1
Fig.11:Wiring plan
+ -
+-
Fig.12:NPN action
+-
+ -
Fig.13:PNP action
18 OPTISWITCH 3100 C-with transistor output
Connecting to voltage supply
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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:
lPotentiometer for switching point adaptation (1)
lDIL switch for mode adjustment -min./max.(2)
lSignal 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.
6.2Adjustment elements
3
4
5
1
2
Fig.14:Oscillator WE60T-Transistor output
1Potentiometer for switching point adaptation
2DIL switch for mode adjustment
3Ground terminal
4Screwed terminals
5Control lamp
Function/Configuration
OPTISWITCH 3100 C-with transistor output 19
Set up
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With the potentiometer you can adapt the switching point to the
solid.It is already preset and must only be modified in special
cases.
By default,the potentiometer of OPTISWITCH 3100 Cis set to
the right stop (>0.02 g/cm³or >0.0008 lbs/in³). In case of very
light-weight solids,turn the potentiometer to the left stop
(>0.008 g/cm³or >0.0003 lbs/in³). OPTISWITCH 3100 Cwill
thus be more sensitive and can detect light-weight solids more
reliably.
For instruments detecting solids in water,these values are not
applicable.The potentiometer is preset and must not be
changed.
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.
detection or overfill protection,min.-min.detection or dry run
protection).
We recommend connecting according 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
Mode max.
Overfill protection transistor con-
ducts
Green
Mode max.
Overfill protection transistor blocks
red
Switching point adaptation (1)
Mode adjustment (2)
Signal lamp (5)
20 OPTISWITCH 3100 C-with transistor output
Set up
29954-EN-060830