KROHNE OPTISWITCH 5200C User manual

Operating Instructions
OPTISWITCH 5200 C,5250 C
with two-wire 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 ............................ 9
3.4Storage and transport ................... 9
4Mounting
4.1General instructions..................... 10
4.2Mounting instructions.................... 13
5Connecting to voltage supply
5.1Preparing the connection ................. 16
5.2Connection steps....................... 16
5.3Wiring plan,single chamber housing......... 17
6Set up
6.1General.............................. 20
6.2Adjustment elements .................... 21
6.3Function chart ......................... 21
6.4Recurring test and function test ............ 22
7Maintenance and fault rectification
7.1Maintenance .......................... 25
7.2Rectify faults .......................... 25
7.3Instrument repair ....................... 26
8Dismounting
8.1Dismounting procedure .................. 27
8.2Disposal ............................. 27
2OPTISWITCH 5200 C,5250 C-with two-wire output
Contents
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9Supplement
9.1Technical data......................... 28
9.2Dimensions ........................... 32
OPTISWITCH 5200 C,5250 C-with two-wire output 3
Contents
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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 5200 C,5250 C-with two-wire output
About this document
30435-EN-060831

2For your safety
2.1Authorised personnel
All operations described in this operating instructions manual
must be carried out only by trained specialist personnel
authorised by the operator.For safety and warranty reasons,
any internal work on the instruments must be carried out only
by personnel authorised by the manufacturer.
2.2Appropriate use
OPTISWITCH 5200 C,5250 Cis a sensor for level detection.
Detailed information on the application range of OPTISWITCH
5200 C,5250 Cis available in chapter "Product description".
2.3Warning about misuse
Inappropriate or incorrect use of the instrument can give rise to
application-specific hazards,e.g.vessel overfill or damage to
system components through incorrect mounting or adjustment.
2.4General safety instructions
OPTISWITCH 5200 C,5250 Cis a high-tech instrument
requiring the strict observance of standard regulations and
guidelines.The user must take note of the safety instructions in
this operating instructions manual,the country-specific instal-
lation standards (e.g.the VDE regulations in Germany)as well
as all prevailing safety regulations and accident prevention
rules.
2.5CE conformity
OPTISWITCH 5200 C,5250 Cis in CE conformity with EMC
(89/336/EWG), fulfils 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/A1:1998 (class B)
-Susceptibility EN 61326:1997/A1:1998
lLVD:EN 61010-1:1993
OPTISWITCH 5200 C,5250 C-with two-wire output 5
For your safety
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2.6SIL conformity
OPTISWITCH 5200 C,5250 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
5XXX".
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 5200 C,5250 C-with two-wire output
For your safety
30435-EN-060831

3Product description
3.1Configuration
The scope of delivery encompasses:
lOPTISWITCH 5200 C,5250 Clevel sensor
lDocumentation
-this operating instructions manual
-Ex specific safety instructions (with Ex versions), if
necessary further certificates
OPTISWITCH 5200 C,5250 Cconsists of the following
components:
lHousing cover
lHousing with electronics
lprocess fitting with tuning fork
1
2
3
Fig.1:OPTISWITCH 5200 C,5250 Cwith plastic housing
1Housing cover
2Housing with electronics
3Process fitting
3.2Principle of operation
OPTISWITCH 5200 C,5250 Cis a level sensor with tuning
fork for level detection.
Scope of delivery
Components
Area of application
OPTISWITCH 5200 C,5250 C-with two-wire output 7
Product description
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It is designed for industrial use in all areas of process
technology and can be used in liquids.
Typical applications are overfill and dry run protection.With a
tuning fork of only 40 mm length,OPTISWITCH 5200 C,5250
Ccan be also mounted,e.g.in pipelines from DN 25.The
small tuning fork allows use in vessels,tanks and pipes.
Thanks to its simple and robust measuring system,OPTI-
SWITCH 5200 C,5250 Cis virtually unaffected by the
chemical and physical properties of the liquid.
It functions even under difficult conditions such as turbulence,
air bubbles,foam generation,buildup,strong external vibration
or changing products.
Fault monitoring
The electronics module of OPTISWITCH 5200 C,5250 C
continuously monitors via frequency evaluation the following
criteria:
lStrong corrosion or damage on the tuning fork
lloss of vibration
lLine break to the piezo drive
If one of these faults is detected,the electronics signals it via a
defined current to the signal conditioning instrument.The
connection cable to the sensor is also monitored on line break
and short-circuit.
The tuning fork is piezoelectrically energised and vibrates at its
mechanical resonance frequency of approx.1200 Hz.The
piezos are fastened mechanically and are hence not subject to
temperature shock limitations.When the tuning fork is
submerged in the product,the frequency changes.This
change is detected by the integrated oscillator,transferred to
the signal conditioning instrument as current value and
converted into a switching command.
Depending on your requirements,OPTISWITCH 5200 C,5250
Cwith two-wire electronics can be connected to different
signal conditioning instruments.Compatible signal condition-
ing instruments are listed under "Technical data".
The exact range of the power supply is stated in the "Technical
data"in the "Supplement".
Physical principle
Power supply
8OPTISWITCH 5200 C,5250 C-with two-wire output
Product description
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3.3Operation
The switching condition of OPTISWITCH 5200 C,5250 Cwith
plastic housing can be checked when the housing is closed
(signal lamp). With the basic setting,products with a density
>0.7g/cm³(>0.025 lbs/in³)can be detected.The instrument
can be adapted if products with lower density should be
measured.
On the electronics module you will find the following indicating
and adjustment elements:
lsignal lamp for indication of the switching condition (green/
red)
lDIL switch for adaptation to the product density
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 ABS.For special versions
PE foam or PE foil is also used.Dispose of the packaging
material via specialised recycling companies.
lStorage and transport temperature see "Supplement -
Technical data -Ambient conditions"
lRelative humidity 20 …85 %
Packaging
Storage and transport tem-
perature
OPTISWITCH 5200 C,5250 C-with two-wire output 9
Product description
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4Mounting
4.1General instructions
In general,OPTISWITCH 5200 C,5250 Ccan be mounted in
any position.The instrument must be mounted in such a way
that the tuning fork is at the height of the requested switching
point.
The tuning fork has lateral markings (notches), marking the
switching point with vertical mounting.The switching point
refers to water with the basic setting of the sensitivity switch
>=0.7g/cm³(>=0.025 lbs/in³). When mounting OPTISWITCH
5200 C,5250 C,make sure that this marking is at the height of
the requested switching point.Keep in mind that the switching
point of the instrument is shifted if the medium has a density
other than water -water =1g/cm³(=0.036 lbs/in³). For
products <0.7g/cm³(<0.025 lbs/in³)and >0.5g/cm³
(>0.018 lbs/in³)the density switch must be set to >=0.5g/cm³.
2
3
14
Fig.2:Vertical mounting
1Switching point approx.13 mm (approx.0.51 in)
2Switching point with lower density
3Switching point with higher density
4Switching point approx.27 mm (approx.1.06 in)
Switching point
10 OPTISWITCH 5200 C,5250 C-with two-wire output
Mounting
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1
Fig.3:Horizontal mounting
1Switching point
1
2
Fig.4:Horizontal mounting (recommended installation location -particularly for
adhesive products)
1Switching point
2Marking with screwed version on top -with flange versions directed to the
flange holes
With flange versions,the fork is directed to the flange holes in
the following way.
Fig.5:Fork position with flange versions
Use the recommended cables (see chapter "Connecting to
power supply")and tighten the cable gland.
You can give your OPTISWITCH 5200 C,5250 Cadditional
protection against moisture penetration by leading the con-
nection cable downward in front of the cable entry.Rain and
Moisture
OPTISWITCH 5200 C,5250 C-with two-wire output 11
Mounting
30435-EN-060831

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.6:Measures against moisture penetration
Do not hold OPTISWITCH 5200 C,5250 Con the tuning fork.
Particularly with flange or tube versions,the tuning fork can be
damaged by the instrument weight.Transport coated instru-
ments very carefully and avoid touching the tuning fork.
Remove the protective cover just before mounting.
The process fitting must be sealed if there is gauge or low
pressure in the vessel.Before use,check if the seal material is
resistant against the measured product and the process
temperature.
The max.permissible pressure is stated in the "Technical
data"in the "Supplement"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 in the instrument!
Applying tightening force on the housing can damage its
internal mechanical parts.
To screw in,use the hexagon above the thread.
Transport
Pressure/Vacuum
Handling
12 OPTISWITCH 5200 C,5250 C-with two-wire output
Mounting
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4.2Mounting instructions
OPTISWITCH 5200 C,5250 Chas a defined thread starting
point.This means that every OPTISWITCH 5200 C,5250 Cis
in the same fork position after being screwed in.Remove
therefore the supplied seal from the thread of OPTISWITCH
5200 C,5250 C.This seal is not required when using a welded
socket with O-ring in front.
Keep in mind that this welded socket is not suitable for coated
instrument versions.
Screw OPTISWITCH 5200 C,5250 Ccompletely into the
welded socket.The later position can be determined already
before welding.Mark the appropriate position of the welded
socket.Before welding,unscrew OPTISWITCH 5200 C,5250
Cand remove the rubber ring from the welded socket.The
welded socket has a marking (notch). Weld the socket with the
notch facing upward,or in case of pipelines,aligned with the
direction of flow.
1
Fig.7:Marking on the welded socket
1Marking
In case of horizontal mounting in adhesive and viscous
products,the surfaces of the tuning fork should be vertical in
order to reduce buildup on the tuning fork.On the screwed
version you will find a marking on the hexagon.With this,you
can check the position of the tuning fork when screwing it in.
When the hexagon touches the seal,the thread can still be
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.
Welded socket
Adhesive products
OPTISWITCH 5200 C,5250 C-with two-wire output 13
Mounting
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When used in adhesive and viscous products,the tuning fork
should protrude into the vessel to avoid buildup.For that
reason,sockets for flanges and mounting bosses should be
avoided when mounting horizontally.
IfOPTISWITCH 5200 C,5250 Cis mounted in the filling
stream,unwanted switching signals may be generated.Mount
OPTISWITCH 5200 C,5250 Cat a location in the vessel
where no disturbing influence from e.g.filling openings,
agitators etc.can occur.
This applies particularly to instrument types with long
extension tube.
Fig.8:Inflowing medium
To minimise flow resistance caused by the tuning fork,
OPTISWITCH 5200 C,5250 Cshould be mounted in such a
way that the surfaces of the blades are parallel to the product
movement.
Due to agitators,vibrations or similar,the level switch can be
subjected to strong lateral forces.For this reason,do not use
an overly long extension tube for OPTISWITCH 5200 C,5250
C,but check if you can mount an OPTISWITCH 5100 C,
5150 Clevel switch on the side of the vessel in horizontal
position.
Extreme vibration caused by the process or the equipment,e.
g.agitators or turbulence in the vessel can cause the extension
tube of OPTISWITCH 5200 C,5250 Cto vibrate in resonance.
This leads to increased stress on the upper weld joint.Should
Inflowing medium
Flows
Agitators
14 OPTISWITCH 5200 C,5250 C-with two-wire output
Mounting
30435-EN-060831

a longer tube version be necessary,you can provide a suitable
support or guy directly above the tuning fork to secure the
extension tube.
This measure applies particularly to applications in Ex areas
category 1Gor WHG.Make sure that the tube is not bent by
this measure.
Fig.9:Lateral straining of OPTISWITCH 5200 C,5250 C
Instruments with enamel coating should be treated very
carefully and shocks should be avoided.Unpack OPTI-
SWITCH 5200 C,5250 Cdirectly before installation.Insert
OPTISWITCH 5200 C,5250 Ccarefully into the vessel
opening and avoid touching any sharp vessel parts.
Enamel coating
OPTISWITCH 5200 C,5250 C-with two-wire output 15
Mounting
30435-EN-060831

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 5200 C,5250 Cto vessel ground (PA),
or in case of plastic vessels,to the next ground potential.On
the side of the instrument housing there is a ground terminal
between the cable entries.This connection serves to drain off
electrostatic charges.InEx applications,the installation
regulations for hazardous areas must be given priority.
The data for power supply are stated in the "Technical data"in
the "Supplement".
OPTISWITCH 5200 C,5250 Cis connected with standard
cable with round cross-section.An outer cable diameter of
5…9mm (0.2…0.35 in)ensures the seal effect of the cable
entry.
If cable with a different diameter or wire cross section is used,
exchange the seal or use an appropriate cable connection.
In hazardous areas,only use approved cable connections for
OPTISWITCH 5200 C,5250 C.
Take note of the corresponding installation regulations for Ex
applications.
5.2Connection 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
16 OPTISWITCH 5200 C,5250 C-with two-wire output
Connecting to voltage supply
30435-EN-060831

3Remove approx.10 cm (4in)of the cable mantle,strip
approx.1cm (0.4in)insulation from the ends of the
individual wires
4Insert the cable into the sensor through the cable entry
5Open the terminals with a screwdriver
6Insert the wire ends into the open terminals according to
the wiring plan
7Tighten the terminals with a screwdriver
8Check the hold of the wires in the terminals by lightly
pulling on them
9Tighten the compression nut of the cable entry,the seal
ring must completely encircle the cable
10 Screw the housing cover back on
The electrical connection is hence finished.
5.3Wiring plan,single chamber housing
The following illustrations apply to the non-Ex as well as to the
EEx d version.
1
4
44
2 3
Fig.10:Material versions,single chamber housing
1Plastic (not with EExd)
2Aluminium
3Stainless steel (not with EExd)
4Filter element for pressure compensation (not with EExd)
Housing overview
OPTISWITCH 5200 C,5250 C-with two-wire output 17
Connecting to voltage supply
30435-EN-060831

SW E60Z
+
12
0,5 g / cm3
0,7 g / cm3
11-36V DC
4
1
2
3
Fig.11:Electronics and connection compartment,single chamber housing
1Control lamp
2DIL switch for sensitivity adjustment
3Ground terminal
4Screwed terminals
We recommend connecting OPTISWITCH 5200 C,5250 Cin
such a way that the switching circuit is open when there is a
level signal,line break or failure (safe condition).
For connection to a signal conditioning instrument dto.Ex,
WHG.The sensor is powered by the connected signal
conditioning instrument.Further information is available in the
Technical data in the Supplement,Ex-technical data are
available in the supplied safety information manual.
The wiring example is applicable for all suitable signal
conditioning instruments.
The control lamp on OPTISWITCH 5200 C,5250 Clights in
general
lred -with covered tuning fork
lgreen -with uncovered tuning fork
Take note of the operating instructions manual of the signal
conditioning instrument.Suitable signal conditioning instru-
ments are listed in the Technical data.
IfOPTISWITCH 5200 C,5250 Cis used in Ex areas as part of
an overfill protection system acc.to WHG,take note for the
regulations in the safety instructions and conformity certifi-
Electronics and connection
compartment
Wiring plan
18 OPTISWITCH 5200 C,5250 C-with two-wire output
Connecting to voltage supply
30435-EN-060831

cates.IfOPTISWITCH with oscillator SW E60ZEX,SW E60Z
EX E1should be operated directly on the analogue input of a
PLC,a suitable safety barrier should be connected.
4321
1 2
+-
Fig.12:Wiring plan,single chamber housing
OPTISWITCH 5200 C,5250 C-with two-wire output 19
Connecting to voltage supply
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6Set up
6.1General
The numbers in brackets refer to the following illustrations.
The switching status of the electronics can be checked when
the cover of the plastic housing is closed (signal lamp). In the
basic setting,products with density >0.7g/cm³(0.025 lbs/in³)
can be detected.For products with lower density,the switch
must be set to >0.5g/cm³(0.018 lbs/in³).
On the electronics module you will find the following indicating
and adjustment elements:
lSignal lamp (1)
lDIL switch for sensitivity adjustment (2)
Mode switch (A/B)
On the signal conditioning instrument via the signal con-
ditioning instrument (only permissible in mode Awhen used
acc.to WHG).
The switching condition can be changed with the A/Bswitch.
You can set the required mode acc.to the "Function chart"(A-
max.detection or overfill protection,B-min.detection or dry
run protection). The integration time can also be modified on
the signal conditioning instrument.
Note:
For test purposes,immerse the tuning fork of OPTISWITCH
5200 C,5250 Calways in liquids.Do not test the function of
OPTISWITCH 5200 C,5250 Cwith the hand.This can
damage the sensor.
Function/Configuration
20 OPTISWITCH 5200 C,5250 C-with two-wire output
Set up
30435-EN-060831