KROHNE OPTISOUND 3020 C User manual

OPTISOUND 3020 C Handbook
Ultrasonic Level Transmitter
Probus PA

2
Contents
OPTISOUND 3020 C • Probus PA
51115-EN-210701
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 .......................................................................................... 5
2.6 EU conformity................................................................................................................... 6
2.7 Fulllment of NAMUR recommendations ......................................................................... 6
2.8 Installation and operation in the USA and Canada ........................................................... 6
3 Product description ................................................................................................................. 7
3.1 Conguration.................................................................................................................... 7
3.2 Principle of operation........................................................................................................ 8
3.3 Packaging, transport and storage..................................................................................... 8
4 Mounting................................................................................................................................. 10
4.1 General instructions ....................................................................................................... 10
4.2 Mounting instructions ..................................................................................................... 12
5 Connecting to power supply................................................................................................. 19
5.1 Preparing the connection ............................................................................................... 19
5.2 Connection procedure.................................................................................................... 20
5.3 Wiring plan, single chamber housing.............................................................................. 21
5.4 Wiring plan, double chamber housing ............................................................................ 22
5.5 Switch-on phase............................................................................................................. 24
6 Set up with the display and adjustment module ................................................................ 25
6.1 Insert display and adjustment module............................................................................ 25
6.2 Adjustment system......................................................................................................... 26
6.3 Setup steps .................................................................................................................... 26
6.4 Menu schematic............................................................................................................. 37
6.5 Saving the parameterisation data................................................................................... 39
7 Maintenanceandfaultrectication...................................................................................... 40
7.1 Maintenance .................................................................................................................. 40
7.2 Rectify faults................................................................................................................... 40
7.3 Exchanging the electronics module................................................................................ 41
7.4 How to proceed if a repair is necessary.......................................................................... 41
8 Dismount................................................................................................................................. 42
8.1 Dismounting steps.......................................................................................................... 42
8.2 Disposal ......................................................................................................................... 42
9 Supplement ............................................................................................................................ 43
9.1 Technical data................................................................................................................ 43
9.2 Device communication Probus PA................................................................................ 46
9.3 Dimensions .................................................................................................................... 50
9.4 Trademark ...................................................................................................................... 51

3
Contents
OPTISOUND 3020 C • Probus PA
51115-EN-210701
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: 2019-03-12

4
1 About this document
OPTISOUND 3020 C • Probus PA
51115-EN-210701
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
OPTISOUND 3020 C • Probus PA
51115-EN-210701
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
OPTISOUND 3020 C is a sensor for continuous level measurement.
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.
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.
2.5 Safety label on the instrument
The safety approval markings and safety tips on the device must be
observed.

6
2 For your safety
OPTISOUND 3020 C • Probus PA
51115-EN-210701
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 FulllmentofNAMURrecommendations
NAMUR is the automation technology user association in the process
industry in Germany. The published NAMUR recommendations are
accepted as the standard in eld instrumentation.
The device fulls the requirements of the following NAMUR recom-
mendations:
• NE 21: 2012 – Electromagnetic compatibility of equipment
• NE 43 – Signal level for fault information from measuring transduc-
ers
• NE 53 – Compatibility of eld devices and display/adjustment
components
For further information see www.namur.de.
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.

7
3 Product description
OPTISOUND 3020 C • Probus PA
51115-EN-210701
3 Product description
3.1 Conguration
The scope of delivery encompasses:
• OPTISOUND 3020 C ultrasonic sensor
• Documentation
– This operating instructions manual
– Ex-specic afety instructions (with Ex versions)
– Operating instructions "Display and adjustment module"
(optional)
– If necessary, further certicates
Information:
Optional instrument features are also described in this operating
instructions manual. The respective scope of delivery results from the
order specication.
The OPTISOUND 3020 C consists of the components:
• Process tting with transducer
• Housing with electronics
• Housing lid with integrated display and adjustment module
(optional)
The components are available in dierent versions.
1
2
3
Fig. 1: OPTISOUND 3020 C, version with plastic housing
1 Housing lid with integrated display and adjustment module (optional)
2 Housing with electronics
3 Processttingwithtransducer
The type label contains the most important data for identication and
use of the instrument:
• Instrument type
• Article and serial number device
Scope of delivery
Constituent parts
Type label

8
3 Product description
OPTISOUND 3020 C • Probus PA
51115-EN-210701
• Article numbers, documentation
• Technical data: For example approvals, process temperature,
process tting/material, signal output, voltage supply, protection
3.2 Principle of operation
OPTISOUND 3020 C is an ultrasonic sensor for continuous level
measurement. It is suitable for liquids and solids in virtually all indus-
tries, particularly in the water and waste water industry.
The transducer of the ultrasonic sensor transmits short ultrasonic
pulses to the measured product. These pulses are reected by
medium surface and received back by the transducer as echoes.
The running time of the ultrasonic pulses from emission to reception
is proportional to the distance and hence the level. The determined
level is converted into an appropriate output signal and outputted as
measured value.
Power supply via the Probus DP/PA segment coupler. A two-wire
cable according to Probus specication serves as carrier of both
power and digital data transmission for multiple sensors. The instru-
ment prole of OPTISOUND 3020 C corresponds to prole specica-
tion version 3.0.
The GSD (instrument master les) and bitmap les necessary for
planning your Probus-DP-(PA) communication network are available
from the download section on our homepage. There you can also nd
the appropriate certicates. In a PDM environment, an EDD (Elec-
tronic Device Description) is also required to enable the full range of
sensor functions (also available as a download).
The backlight of the display and adjustment module is powered by the
sensor. Prerequisite is a certain level of operating voltage.
The data for power supply are specied in chapter "Technical data".
3.3 Packaging, transport and storage
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 cardboard. For special versions, PE foam or PE
foil is also used. Dispose of the packaging material via 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.
Application area
Functional principle
Power supply and bus
communication
GSD/EDD
Packaging
Transport
Transport inspection

9
3 Product description
OPTISOUND 3020 C • Probus PA
51115-EN-210701
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.
Storage
Storage and transport
temperature
Lifting and carrying

10
4 Mounting
OPTISOUND 3020 C • Probus PA
51115-EN-210701
4 Mounting
4.1 General instructions
Select an installation position you can easily reach for mounting and
connecting as well as later retrotting of a display and adjustment
module. The housing can be rotated by 330° without the use of any
tools. You can also install the display and adjustment module in four
dierent positions (each displaced by 90°).
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.
Fig. 2: Measures against moisture ingress
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.
The reference plane for the measuring range is the lower edge of the
transducer.
Make sure that a minimum distance from the reference plane - the
so-called dead zone, in which measurement is not possible - is
Installation position
Moisture
Cable entries - NPT
thread
Cable glands
Referenceplanefor
measuring range

11
4 Mounting
OPTISOUND 3020 C • Probus PA
51115-EN-210701
maintained. The exact value of the dead zone is stated in chapter
"Technical data".
12
Fig. 3: Minimum distance to the max. level
1 Dead zone
2 Reference plane
Information:
If the medium reaches the transducer, buildup can form on it and
cause faulty measurements later on.
132
100%
0%
Fig. 4: Measuring range (operating range) and max. measuring distance
1 full
2 empty (max. measuring distance)
3 Measuring range
Gauge pressure in the vessel does not inuence OPTISOUND 3020
C. Low pressure or vacuum does, however, damp the ultrasonic
pulses. This inuences the measuring result, particularly if the level
is very low. With pressures under -0.2 bar (-20 kPa) you should use a
dierent measuring principle, e.g. radar or guided radar (TDR).
Pressure/Vacuum

12
4 Mounting
OPTISOUND 3020 C • Probus PA
51115-EN-210701
4.2 Mounting instructions
Screw OPTISOUND 3020 C into the mounting socket with an ap-
propriate spanner applied to the hexagon of the process tting. Max.
torque see chapter "Technical data".
Warning:
The housing must not be used to screw the instrument in! Applying
tightening force can damage internal parts of the housing.
When mounting the sensor, keep a distance of at least 200 mm
(7.874 in) to the vessel wall. If the sensor is installed in the center of
dished or round vessel tops, multiple echoes can arise. These can,
however, be suppressed by an appropriate adjustment (see chapter
"Setup").
1
2
> 200 mm
Fig. 5: Mounting on round vessel tops
1 Reference plane
2 Vessel center or symmetry axis
If this distance cannot be maintained, a false signal suppression
should be carried out during setup. This applies particularly if buildup
on the vessel wall is expected. In such cases, we recommend repeat-
ing the false signal suppression at a later date with existing buildup.
In vessels with conical bottom it can be advantageous to mount the
sensor in the centre of the vessel, as measurement is then possible
down to the bottom.
Screwing in
Installation position

13
4 Mounting
OPTISOUND 3020 C • Probus PA
51115-EN-210701
Fig. 6: Vessel with conical bottom
Socket pieces should be dimensioned so that the lower end of the
transducer protrudes at least 10 mm (0.394 in) out of the socket.
~ 10 mm
Fig. 7: Recommended socket mounting
If the reective properties of the medium are good, you can mount
OPTISOUND 3020 C on sockets which are higher than the length of
the transducer. You will nd recommended values for socket heights in
the following illustration. The socket end should be smooth and burr-
free, if possible also rounded. Carry out a false signal suppression.
Mounting socket

14
4 Mounting
OPTISOUND 3020 C • Probus PA
51115-EN-210701
> 10 mm
d
h
dh
100 mm/4"
150 mm/6"
200 mm/8"
300 mm/12"
400 mm/16"
500 mm/20"
Fig. 8: Deviating socket dimensions
In liquids, direct the sensor as perpendicular as possible to the prod-
uct surface to achieve optimum measurement results.
Fig. 9: Alignment in liquids
To reduce the min. distance to the medium, you can also mount OP-
TISOUND 3020 C with a beam deector. By doing this, it is possible
to ll the vessel nearly to maximum. Such an arrangement is suitable
primarily for open vessels such as e.g. overow basins.
45°
~200 mm
(7.87")
~
400 mm x 400 mm
(15.75" x 15.75")
Fig.10:Beamdeector
The ultrasonic sensor should be installed at a location where no
installations cross the ultrasonic beam.
Vessel installations such as for example, ladders, limit switches, heat-
ing spirals, struts etc. can cause false echoes that interfere with the
useful echo. Make sure when planning your measuring site that the
ultrasonic signals have a "clear view" to the measured product.
In case of existing vessel installations, a false signal suppression
should be carried out during setup.
Sensor orientation
Vessel installations

15
4 Mounting
OPTISOUND 3020 C • Probus PA
51115-EN-210701
If large vessel installations such as struts or supports cause false
echoes, these can be attenuated through supplementary measures.
Small, inclined sheet metal or plastic baes above the installations
scatter the ultrasonic signals and avoid direct false echoes.
α
α
α
α
α
α
Fig.11:Coverat,large-areaproleswithdeectors
If there are agitators in the vessel, a false signal suppression should
be carried out with the agitators in motion. This ensures that the
interfering reections from the agitators are saved with the blades in
dierent positions.
Fig. 12: Agitators
Do not mount the instruments in or above the lling stream. Make sure
that you detect the product surface, not the inowing product.
Agitators
Inowingmedium

16
4 Mounting
OPTISOUND 3020 C • Probus PA
51115-EN-210701
Fig.13:Inowingliquid
Through the action of lling, stirring and other processes in the vessel,
dense foams which considerably damp the emitted signals may form
on the medium surface.
If foams are causing measurement errors, the sensor should be used
in a standpipe or, alternatively, the more suitable guided radar sen-
sors (TDR) should be used.
Guided wave radar is unaected by foam generation and is particu-
larly suitable for such applications.
If there are strong air currents in the vessel, e.g. due to strong winds
in outdoor installations or air turbulence, e.g. by cyclone extraction
you should mount OPTISOUND 3020 C in a standpipe or use a dier-
ent measuring principle, e.g. radar or guided radar (TDR).
By using a standpipe (surge or bypass tube), the inuence of vessel
installations, foam generation and turbulence is excluded.
Standpipes must extend all the way down to the requested min. level,
as measurement is only possible within the tube.
Foam
Air turbulences
Standpipe measurement

17
4 Mounting
OPTISOUND 3020 C • Probus PA
51115-EN-210701
max.
min.
1
Fig. 14: Standpipe in the tank
1 Vent hole: ø 5 … 10 mm (0.197 … 0.394 in)
OPTISOUND 3020 C can be used from tube diameters of 50 mm
(1.969 in).
Avoid large gaps and thick welding joints when connecting the tubes.
Generally carry out a false signal suppression.
Measurement in a standpipe is not recommended for extremely
adhesive products.
The short examples give you introductory information on ow
measurement. Detailed planning information is available from ume
manufacturers and in special literature.
3 ... 4 hmax
≥ 50 mm
90°
23
1
hmaxdmin
≥ 2 mm x hmax
90°
42 3
Fig. 15: Flow measurement with rectangular overfall: dmin. = min. distance of
the sensor (see chapter "Technical data"); hmax.=max.llingoftherectangular
spillway
1 Overoworice(sideview)
2 Headwater
3 Tailwater
4 Overfallorice(viewfromtailwater)
In general, the following points must be observed:
Flow measurement with
rectangular overfall

18
4 Mounting
OPTISOUND 3020 C • Probus PA
51115-EN-210701
• Install the sensor on the headwater side
• Installation in the centre of the ume and vertical to the liquid
surface
• Distance to the overfall orice
• Distance of orice opening above ground
• Min. distance of the orice opening to tailwater
• Min. distance of the sensor to max. storage level
2
3 ... 4 x hmax
90°
hmax
d
B
1
Fig.16:FlowmeasurementwithKhafagi-Venturiume:d=Min.distancetosen-
sor; hmax.=max.llingoftheume;B=tightestconstrictionintheume
1 Position sensor
2 Venturiume
In general, the following points must be observed:
• Installation of the sensor at the inlet side
• Installation in the centre of the ume and vertical to the liquid
surface
• Distance to the Venturi ume
• Min. distance of the sensor to max. storage level
Flow measurement with
KhafagiVenturiume

19
5 Connecting to power supply
OPTISOUND 3020 C • Probus PA
51115-EN-210701
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
• If voltage surges are expected, overvoltage arresters should be
installed according to Probus specications
In hazardous areas you must take note of the respective regulations,
conformity and type approval certicates of the sensors and power
supply units.
Power supply is provided by a Probus DP/PA segment coupler. The
power supply range can dier depending on the instrument version.
The data for power supply are specied in chapter "Technical data".
Connection is made with screened cable according to the Probus
specication. Power supply and digital bus signal are carried over the
same two-wire connection cable.
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.
Please make sure that your installation is carried out according to the
Probus specication. In particular, make sure that the termination of
the bus is done with appropriate terminating resistors.
On the instrument with cable entry ½ NPT and plastic housing there is
a metallic ½" threaded insert moulded into the plastic housing.
Caution:
No grease should be used when screwing the NPT cable gland or
steel tube into the threaded insert. Standard grease can contain
additives that corrode the connection between threaded insert and
housing. This would inuence the stability of the connection and the
tightness of the housing.
In systems with potential equalisation, connect the cable screening
directly to ground potential at the power supply unit, in the connection
box and at the sensor. The screen in the sensor must be connected
directly to the internal ground terminal. The ground terminal outside
on the housing must be connected to the potential equalisation (low
impedance).
In systems without potential equalisation, connect the cable screen
directly to ground potential at the power supply unit and at the sensor.
In the connection box or T-distributor, the screen of the short stub to
the sensor must not be connected to ground potential or to another
cable screen. The cable screens to the power supply unit and to the
Note safety instructions
Take note of safety
instructions for Ex
applications
Voltage supply
Connection cable
Cable gland ½ NPT
Cable screening and
grounding

20
5 Connecting to power supply
OPTISOUND 3020 C • Probus PA
51115-EN-210701
next distributor must be connected to each other and also connected
to ground potential via a ceramic capacitor (e.g. 1 nF, 1500 V). The
low frequency potential equalisation currents are thus suppressed,
but the protective eect against high frequency interference signals
remains.
The total capacitance of the cable and of all capacitors must not
exceed 10 nF in Ex applications.
Take note of the corresponding installation regulations for Ex applica-
tions. In particular, make sure that no potential equalisation currents
ow over the cable screen. In case of grounding on both sides this
can be achieved by the use of a capacitor or a separate potential
equalisation.
5.2 Connection procedure
Proceed as follows:
1. Unscrew the housing lid
2. If a display and adjustment module is installed, remove it by turn-
ing it to the left
3. Loosen compression nut of the cable gland and remove blind
plug
4. 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
5. Insert the cable into the sensor through the cable entry
6. Lift the opening levers of the terminals with a screwdriver (see
following illustration)
7. Insert the wire ends into the open terminals according to the wir-
ing plan
Fig. 17: Connection steps 6 and 7
Connection cable
for Ex applications