KROHNE OPTISWITCH 3200 C User manual

OPTISWITCH 3200 C Handbook
Vibrating Level Switch
NAMUR

2
Contents
OPTISWITCH 3200 C • NAMUR
31357-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........................................................................................................ 8
3.3 Adjustment ....................................................................................................................... 8
3.4 Storage and transport....................................................................................................... 9
4 Mounting................................................................................................................................. 10
4.1 General instructions ....................................................................................................... 10
4.2 Mounting instructions ..................................................................................................... 11
5 Connecting to power supply................................................................................................. 16
5.1 Preparing the connection ............................................................................................... 16
5.2 Connection procedure.................................................................................................... 16
5.3 Wiring plan, single chamber housing.............................................................................. 17
6 Setup ....................................................................................................................................... 19
6.1 General information........................................................................................................ 19
6.2 Adjustment elements...................................................................................................... 19
6.3 Function table................................................................................................................. 20
6.4 Proof test (SIL) ............................................................................................................... 21
7 Maintenanceandfaultrectication...................................................................................... 23
7.1 Maintenance .................................................................................................................. 23
7.2 Rectify faults................................................................................................................... 23
7.3 Exchanging the electronics module................................................................................ 24
7.4 How to proceed if a repair is necessary.......................................................................... 25
8 Dismount................................................................................................................................. 26
8.1 Dismounting steps.......................................................................................................... 26
8.2 Disposal ......................................................................................................................... 26
9 Supplement ............................................................................................................................ 27
9.1 Technical data ................................................................................................................ 27
9.2 Dimensions .................................................................................................................... 30
9.3 Trademark ...................................................................................................................... 32

3
Contents
OPTISWITCH 3200 C • NAMUR
31357-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 3200 C • NAMUR
31357-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 3200 C • NAMUR
31357-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 3200 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 3200 C • NAMUR
31357-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 3200 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 3200 C • NAMUR
31357-EN-210702
3 Product description
3.1 Conguration
The scope of delivery encompasses:
• OPTISWITCH 3200 C point level switch
• Documentation
– This operating instructions manual
– Exspecicsafetyinstructions(withExversions),ifnecessary
furthercerticates
The OPTISWITCH 3200 C consists of the components:
• Housing lid
• Housing with electronics
• Processttingwithtuningfork
1
2
3
Fig. 1: OPTISWITCH 3200 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.
Scope of delivery
Constituent parts
Type label

8
3 Product description
OPTISWITCH 3200 C • NAMUR
31357-EN-210702
3.2 Principle of operation
OPTISWITCH 3200 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 3200 C is virtu-
allyunaectedbythechemicalandphysicalpropertiesofthebulk
solid.
It also works when subjected to strong external vibrations or changing
products.
Solid detection in water
If OPTISWITCH 3200 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 3200 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 3200 C continuously moni-
tors 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.
OPTISWITCH 3200 C with NAMUR electronics can be connected
todierentNAMURampliersdependingonyourrequirements.The
specicationsforNAMURampliersareavailableinthe"Technical
data".
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:
• Control lamp for indication of the switching status (yellow)
• Potentiometer for adaptation to the product density
• Mode switch to select the switching condition (reverse character-
istics)
• Simulation key
Application area
Functional principle
Voltage supply

9
3 Product description
OPTISWITCH 3200 C • NAMUR
31357-EN-210702
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.
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.
Packaging
Transport
Transport inspection
Storage
Storage and transport
temperature
Lifting and carrying

10
4 Mounting
OPTISWITCH 3200 C • NAMUR
31357-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 3200 C must be mounted vertically. 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 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 3200 C • NAMUR
31357-EN-210702
Fig. 2: Measures against moisture ingress
Do not hold OPTISWITCH 3200 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
Make sure that the max. permissible tensile load of the suspension
cable is not exceeded. The danger of this happening exists particu-
Transport
Pressure/Vacuum
Handling
Cable entries - NPT
thread
Cable glands
Tensile load

12
4 Mounting
OPTISWITCH 3200 C • NAMUR
31357-EN-210702
larly with very heavy solids and large meas. lengths.The max. permis-
sible load is stated in chapter "Technical data".
In silos for bulk solids, material cones can form and change the
switching point. Please keep this in mind when installing the sensor
in the vessel.We recommend selecting an installation location where
the vibrating fork detects an average value of the material cone.
The tuning fork must be mounted in a way that takes the arrangement
ofthellingandemptyingaperturesintoaccount.
To compensate measurement errors caused by the material cone in
cylindrical vessels, the sensor must be mounted at a distance of d/6
from the vessel wall.
dd
d
6
d
6
Fig. 3: Filling and emptying centred
Material cone

13
4 Mounting
OPTISWITCH 3200 C • NAMUR
31357-EN-210702
d
d
6
1
2
3
Fig. 4: Filling in the centre, emptying laterally
1 OPTISWITCH 3200 C
2 Discharge opening
3 Filling opening
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.
IfOPTISWITCH3200Cismountedinthellingstream,unwanted
false measurement signals can be generated. For this reason, mount
OPTISWITCH 3200 C at a position in the vessel where no disturbanc-
es,e.g.fromllingopenings,agitators,etc.,canoccur.
Mounting socket
Inowingmedium

14
4 Mounting
OPTISWITCH 3200 C • NAMUR
31357-EN-210702
Fig.5:Inowingmedium
To make sure the tuning fork of OPTISWITCH 3200 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. 6: Flow orientation of the tuning fork
1 Marking with screwed version
2 Directionofow
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.
Productow
Baeprotectionagainst
falling rocks

15
4 Mounting
OPTISWITCH 3200 C • NAMUR
31357-EN-210702
> 125 mm
(> 5")
> 120 mm
(> 4.7")
Fig.7:Baeforprotectionagainstmechanicaldamage

16
5 Connecting to power supply
OPTISWITCH 3200 C • NAMUR
31357-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.
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 following diagrams.Take
note of the general installation regulations. As a rule, connect OPTIS-
WITCH 3200 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applications,theinstal-
lation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
screening. 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 3200 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 lid
Note safety instructions
Take note of safety
instructions for Ex
applications
Voltage supply
Connection cable
Connection cable
for Ex applications

17
5 Connecting to power supply
OPTISWITCH 3200 C • NAMUR
31357-EN-210702
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.

18
5 Connecting to power supply
OPTISWITCH 3200 C • NAMUR
31357-EN-210702
1
4
44
2 3
Fig. 9: Material versions, single chamber housing
1 Plastic
2 Aluminium
3 Stainless steel
4 Filter element for air pressure compensation
ForconnectionoftheamplieraccordingtoNAMUR(IEC60947-5-6,
EN50227).Youcanndfurtherinformationinthe"Technical data".
Furtherinformationyouwillndinthe"Technical data", "Ex technical
data"arespeciedintheattached"Safety instructions manual".
12
+
+
-
-
Fig. 10: Wiring plan, single chamber housing
External simulation key
In addition to the test key on the electronics module, you can connect
an external key to start the test procedure. Connect the key according
to the following wiring plan. In shipping condition, terminals 3 and 4
are bridged.
For additional information see "Recurring function test".
+-
+-
1234
3
2
1
Fig. 11: Wiring plan - External simulation key
1 NAMURamplier
2 Bridge
3 External simulation key
Housing overview
Wiring plan

19
6 Setup
OPTISWITCH 3200 C • NAMUR
31357-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)
• Simulation key (3)
• Signal lamp (6)
6.2 Adjustment elements
4
5
6
3
1
2
Simulation
NAMUR IEC 60947-5-6
VB60N
Fig. 12: Electronics and connection compartment - NAMUR output
1 Potentiometer for adjustment of the density range
2 DIL switch for characteristics reversal
3 Simulation key
4 Ground terminal
5 Connection terminals
6 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 3200 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 3200 C will thus be more sensitive and
can detect light-weight solids more reliably.
For instruments detecting solids in water, these settings are not ap-
plicable.The density range is preset and must not be changed.
Function/Conguration
Electronics and connec-
tion compartment
Adjustment of the density
range (1)

20
6 Setup
OPTISWITCH 3200 C • NAMUR
31357-EN-210702
The characteristics reversal can be carried out with the DIL switch.
You can choose between falling characteristic curve (switch position
max.) and rising characteristic curve (switch position min.).This al-
lows you to output the desired current.
Modes
• min. - rising characteristic curve (High current when immersed)
• max. - falling characteristics (Low current when immersed)
The NAMUR output can be switched over to falling or rising charac-
teristics (see also "Function table").
The simulation key is located in a recess on the upper side of the
electronics module. Push the simulation key with a suitable object
(screwdriver, pen, etc.).
When the key is pushed, a line break between sensor and process-
ing unit is simulated. The signal lamp on the sensor extinguishes. The
measuring system must signal a fault and take on a safe state when
the key is pushed.
Keep in mind that downstream connected instruments will be acti-
vated during operation. This allows you to check the correct function
of the measuring system.
Control lamp (LED) for indication of the switching condition
• yellow=Highcurrent≥2.2mA
• dark=Lowcurrent≤1.0mA
• yellow(ashing)=Failure≤1.0mA
6.3 Function table
Level switch OPTISWITCH 3200 C
The following table provides an overview of the switching conditions
depending on the set mode and the level.
Note:
ThemodesettingontheNAMURampliermustbeselectedinsuch
a way that the switching output takes on safe state in case of failure (I
≤1mA).
Level Signal current - Sensor Control lamp
Falling characteristics max. ≥2.2mA
Falling characteristics max. ≤1mA
Characteristics reversal
(2)
Simulation key (3)
Signal lamp (6)