KROHNE OPTISWITCH 3100 C User manual

Operating Instructions
OPTISWITCH 3100 C
- two-wire
Document
ID: 29955

2
Contents
OPTISWITCH 3100 C • - two-wire
29955-EN-140630
Contents
1 About this document
1.1 Function ........................................................................................................................... 4
1.2 Target group..................................................................................................................... 4
1.3 Symbols used................................................................................................................... 4
2 For your safety
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 CE conformity................................................................................................................... 6
2.7 SIL conformity .................................................................................................................. 6
2.8 Safety instructions for Ex areas ........................................................................................ 6
3 Product description
3.1 Conguration.................................................................................................................... 7
3.2 Principle of operation........................................................................................................ 7
3.3 Operation ......................................................................................................................... 8
3.4 Storage and transport....................................................................................................... 8
4 Mounting
4.1 General instructions ....................................................................................................... 10
4.2 Mounting instructions ..................................................................................................... 11
5 Connecting to power supply
5.1 Preparing the connection ............................................................................................... 14
5.2 Connection procedure.................................................................................................... 14
5.3 Wiring plan, single chamber housing.............................................................................. 15
6 Setup
6.1 General information........................................................................................................ 17
6.2 Adjustment elements...................................................................................................... 17
6.3 Function chart ................................................................................................................ 18
7 Maintenanceandfaultrectication
7.1 Maintenance .................................................................................................................. 21
7.2 Rectify faults................................................................................................................... 21
7.3 Exchanging the electronics module................................................................................ 22
7.4 Instrument repair ............................................................................................................ 23
8 Dismount
8.1 Dismounting steps.......................................................................................................... 24
8.2 Disposal ......................................................................................................................... 24
9 Supplement
9.1 Technical data ................................................................................................................ 25
9.2 Dimensions .................................................................................................................... 28

3
Contents
OPTISWITCH 3100 C • - two-wire
29955-EN-140630
Supplementary documentation
Information:
Supplementary documents appropriate to the ordered version come
withthedelivery.Yo u canndthemlistedinchapter"Product descrip-
tion".
Instructions manuals for accessories and replacement parts
Tip:
To ensure reliable setup and operation of your OPTISWITCH 3100
C,weoeraccessoriesandreplacementparts.Thecorresponding
documentations are:
•Operatinginstructionsmanual"Oscillator"
Editing status:2014-05-26

4
1 About this document
OPTISWITCH 3100 C • - two-wire
29955-EN-140630
1 About this document
1.1 Function
This operating instructions manual provides all the information you
need for mounting, connection and setup as well as important instruc-
tionsformaintenanceandfaultrectication.Pleasereadthisinforma-
tion 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 specialist
personnel. The contents of this manual should be made available to
these personnel and put into practice by them.
1.3 Symbols 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.
SIL applications
This symbol indicates instructions for functional safety which must be
taken into account particularly for safety-relevant applications.
•List
The dot set in front indicates a list with no implied sequence.
→ Action
This arrow indicates a single action.
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 • - two-wire
29955-EN-140630
2 For your safety
2.1 Authorised personnel
All operations described in this operating instructions manual must
be carried out only by trained specialist 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 the instrument can give rise to
application-specichazards,e.g.vesseloverllordamagetosystem
components through incorrect mounting or adjustment.
2.4 General safety instructions
This is a state-of-the-art instrument complying with all prevailing
regulations and guidelines. The instrument must only be operated in a
technicallyawlessandreliablecondition.Theoperatorisresponsible
for the trouble-free operation of the instrument.
During the entire duration of use, the user is obliged to determine the
compliance of the necessary occupational safety measures with the
current valid rules and regulations and also take note of new regula-
tions.
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.
The safety approval markings and safety tips on the device must also
be observed.

6
2 For your safety
OPTISWITCH 3100 C • - two-wire
29955-EN-140630
2.5 Safety label on the instrument
The safety approval markings and safety tips on the device must be
observed.
2.6 CE conformity
ThisdevicefulllsthelegalrequirementsoftheapplicableECguide-
lines.ByattachingtheCEmark,weprovideconrmationofsuccess-
ful testing.
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 Safety instructions for Ex areas
PleasenotetheEx-specicsafetyinformationforinstallationandop-
eration in Ex areas. These safety instructions are part of the operating
instructions manual and come with the Ex-approved instruments.

7
3 Product description
OPTISWITCH 3100 C • - two-wire
29955-EN-140630
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 cover
•Housing with electronics
•Processttingwithtuningfork
1
2
3
Fig. 1: OPTISWITCH 3100 C - with plastic housing
1 Housing cover
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 • - two-wire
29955-EN-140630
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 monitors continu-
ously the following criteria:
•Correct vibrating frequency
•Linebreaktothepiezodrive
If one of these faults is detected, the electronics signals this via a
dened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 electronics module and
converted into a switching command.
Depending on your requirements, OPTISWITCH 3100 C with two-
wireelectronicscanbeconnectedtodierentsignalconditioning
instruments. Compatible signal conditioning instruments are listed in
chapter"Technical data".
Thedataforpowersupplyarespeciedinchapter"Technical data".
3.3 Operation
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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 changeover for selection of the output current
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 • - two-wire
29955-EN-140630
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 %
Transport
Transport inspection
Storage
Storage and transport
temperature

10
4 Mounting
OPTISWITCH 3100 C • - two-wire
29955-EN-140630
4 Mounting
4.1 General instructions
Make sure that all parts of the instrument coming in direct contact
with the process, especially the sensor element, process seal and
processtting,aresuitablefortheexistingprocessconditions,such
as process pressure, process temperature as well as the chemical
properties of the medium.
Youcanndthespecicationsinchapter"Technical data"andonthe
nameplate.
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 OPTISWITCH 3100 C additional protection against
moisture penetration by leading the connection cable downward in
front of the cable entry. 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pro-
cesses)oroncooledorheatedvessels.
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 seal 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.
Suitability for the process
conditions
Switching point
Moisture
Transport
Pressure/Vacuum

11
4 Mounting
OPTISWITCH 3100 C • - two-wire
29955-EN-140630
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.
4.2 Mounting instructions
The vibrating element should protrude into the vessel to avoid
buildup.Forthatreason,avoidusingmountingbossesforanges
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.
Handling
Socket
Filling opening
Horizontal installation

12
4 Mounting
OPTISWITCH 3100 C • - two-wire
29955-EN-140630
20°
Fig. 4: Horizontal installation
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

13
4 Mounting
OPTISWITCH 3100 C • - two-wire
29955-EN-140630
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

14
5 Connecting to power supply
OPTISWITCH 3100 C • - two-wire
29955-EN-140630
5 Connecting to power supply
5.1 Preparing the connection
Always keep in mind the following safety instructions:
•Connect only in the complete absence of line voltage
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 operating voltage according to the following diagrams.
Take note of the general installation regulations. As a rule, connect
OPTISWITCH3100Cto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oelectrostaticcharges.InExapplica-
tions,theinstallationregulationsforhazardousareasmustbegiven
priority.
Thedataforpowersupplyarespeciedinchapter"Technical data".
The instrument is connected with standard two-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.
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.
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 cover
2. Loosen compression nut of the cable entry gland
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)
Note safety instructions
Take note of safety
instructions for Ex
applications
Voltage supply
Connection cable
Connection cable
for Ex applications

15
5 Connecting to power supply
OPTISWITCH 3100 C • - two-wire
29955-EN-140630
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 cover 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.
1
4
44
2 3
Fig. 9: Material versions, single chamber housing
1 Plastic (not with EEx d)
2 Aluminium
3 Stainless steel (not with EEx d)
4 Filter element for pressure compensation (not with EEx d)
Housing overview

16
5 Connecting to power supply
OPTISWITCH 3100 C • - two-wire
29955-EN-140630
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3100Ciscorrectlysetto"max.",
the control lamp on OPTISWITCH 3100 C lights.
•red - with submerged vibrating element
•green - with uncovered vibrating element
Take note of the operating instructions manual of the signal condition-
ing instrument. Suitable signal conditioning instruments are listed in
chapter"Technical data".
1
Fig. 10: Wiring plan
1 Voltage supply
Wiring plan

17
6 Setup
OPTISWITCH 3100 C • - two-wire
29955-EN-140630
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adaptationtotheproductdensity(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 . If the instrument is used in con-
junction with a signal conditioning instrument, always set the mode
switch(2)onOPTISWITCH3100Cto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 connected
instruments or devices.
6.2 Adjustment elements
3
4
1
2
5
Fig. 11: Electronics and connection compartment - two-wire output
1 Potentiometer for switching point adaptation
2 DIL switch for mode adjustment
3 Ground terminal
4 Connection terminals
5 Control lamp
Function/Conguration
Electronics and terminal
compartment

18
6 Setup
OPTISWITCH 3100 C • - two-wire
29955-EN-140630
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.
For instruments detecting solids in water, these settings are not
applicable. The switching point adaptation is preset and must not be
changed.
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accordingtothe"Func-
tion chart"(max.-max.detectionoroverllprotection,min.-min.
detectionordryrundetection)onthesignalconditioninginstrument.
When used on a control system, the following values apply:
•Mode min.
– Vibrating element uncovered - 16 mA ±1 mA
– Vibrating element covered - 8 mA ±1 mA
•Mode max.
– Vibrating element uncovered - 8 mA ±1 mA
– Vibrating element covered - 16 mA ±1 mA
Control lamp for indication of the switching status
•green = 8 mA
•red = 16 mA
•red(ashing)=Failure(<2.3mA)
6.3 Function chart
Level switch OPTISWITCH 3100 C
The following chart provides an overview of the switching conditions
depending on the set mode and the level.
Mode on the sensor Level Signal current - Sensor Signal lamp - sensor
Max.
Overowprotection
8 mA
Green
Max.
Overowprotection
approx. 16 mA
Red
Switching point adapta-
tion (1)
Mode adjustment (2)
Signal lamp (5)

19
6 Setup
OPTISWITCH 3100 C • - two-wire
29955-EN-140630
Mode on the sensor Level Signal current - Sensor Signal lamp - sensor
Min.
Dry run protection
approx. 8 mA
Green
Min.
Dry run protection
approx. 16 mA
Red
Fault message
(min./max.mode)
any <2.3mA
ashesred
OPTISWITCH 3100 C level switch with signal conditioning
instrument1)
The following chart provides an overview of the switching conditions
depending on the adjusted mode of the signal conditioning instru-
ment and the level.
Note:
Keep in mind that the mode switch of OPTISWITCH 3100 C must be
alwayssetto"max.".
Mode on the signal
conditioning in-
strument
Level Signal current -
Sensor
Signal lamp - sen-
sor
Signal lamp - sig-
nal conditioning
instrument
Mode A
Overowprotection
approx. 8 mA
Green
Mode A
Overowprotection
approx. 16 mA
Red
Mode B
Dry run protection
approx. 16 mA
Red
1) Youwillndsuitablesignalconditioninginstrumentsinchapter"Technical
data".

20
6 Setup
OPTISWITCH 3100 C • - two-wire
29955-EN-140630
Mode on the signal
conditioning in-
strument
Level Signal current -
Sensor
Signal lamp - sen-
sor
Signal lamp - sig-
nal conditioning
instrument
Mode B
Dry run protection
approx. 8 mA
Green
Fault message
(modeA/B)
any <2.3mA
ashesred