KROHNE OPTISOUND 3020 C User manual

OPTISOUND 3020 C Handbook
Ultrasonic Level Transmitter
Four-wire 4 … 20 mA/HART

2
Contents
OPTISOUND 3020 C • Four-wire 4 … 20 mA/HART
30508-EN-220310
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 EU conformity................................................................................................................... 5
2.6 FulllmentofNAMURrecommendations ......................................................................... 6
2.7 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, double chamber housing ............................................................................ 21
5.4 Switch-on phase............................................................................................................. 23
6 Set up with the display and adjustment module ................................................................ 24
6.1 Insert display and adjustment module............................................................................ 24
6.2 Adjustment system......................................................................................................... 25
6.3 Setup steps .................................................................................................................... 25
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 Dimensions .................................................................................................................... 46
9.3 Trademark ...................................................................................................................... 48

3
Contents
OPTISOUND 3020 C • Four-wire 4 … 20 mA/HART
30508-EN-220310
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: 2022-03-07

4
1 About this document
OPTISOUND 3020 C • Four-wire 4 … 20 mA/HART
30508-EN-220310
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.
Disposal
This symbol indicates special instructions for disposal.

5
2 For your safety
OPTISOUND 3020 C • Four-wire 4 … 20 mA/HART
30508-EN-220310
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 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.

6
2 For your safety
OPTISOUND 3020 C • Four-wire 4 … 20 mA/HART
30508-EN-220310
Electromagnetic compatibility
The instruments are designed for use in an industrial environment.
Nevertheless, electromagnetic interference from electrical conductors
and radiated emissions must be taken into account, as is usual with a
class A instrument according to EN 61326-1. If the instrument is used
inadierentenvironment,itselectromagneticcompatibilitywithother
devices must be ensured by suitable measures.
2.6 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.
2.7 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 • Four-wire 4 … 20 mA/HART
30508-EN-220310
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 cover, optionally available with display and adjustment
module
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 • Four-wire 4 … 20 mA/HART
30508-EN-220310
• 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.
Four-wire electronics with separate power supply.
Thesupplyvoltagerangecandierdependingontheinstrument
version.
Thedataforpowersupplyarespeciedinchapter"Technical data".
Measuredvaluetransmissioniscarriedoutviathe4…20mA/HART
output separate from power supply.
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.
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
Application area
Functional principle
Voltage supply
Packaging
Transport
Transport inspection
Storage

9
3 Product description
OPTISOUND 3020 C • Four-wire 4 … 20 mA/HART
30508-EN-220310
• 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 and transport
temperature
Lifting and carrying

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4Mounting
OPTISOUND 3020 C • Four-wire 4 … 20 mA/HART
30508-EN-220310
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.
Installation position
Moisture
Cable entries - NPT
thread
Cable glands
Referenceplanefor
measuring range

11
4Mounting
OPTISOUND 3020 C • Four-wire 4 … 20 mA/HART
30508-EN-220310
Makesurethatablockingdistancebelowthereferenceplaneismain-
tained in which a measurement is not possible.The exact value of the
blocking distance is stated in chapter " Technical data".
12
Fig. 3: Blocking distance to the max. level
1 blocking distance
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 • Four-wire 4 … 20 mA/HART
30508-EN-220310
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 • Four-wire 4 … 20 mA/HART
30508-EN-220310
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nozzle.
~ 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.
Nozzle

14
4Mounting
OPTISOUND 3020 C • Four-wire 4 … 20 mA/HART
30508-EN-220310
> 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 me-
dium surface to achieve optimum measurement results.
Fig. 9: Alignment in liquids
To reduce the blocking distance to the medium, you can also mount
OPTISOUND3020Cwithabeamdeector.Bydoingthis,itispos-
sible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 • Four-wire 4 … 20 mA/HART
30508-EN-220310
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mediumsurface,nottheinowingproduct.
Agitators
Inowingmedium

16
4Mounting
OPTISOUND 3020 C • Four-wire 4 … 20 mA/HART
30508-EN-220310
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 • Four-wire 4 … 20 mA/HART
30508-EN-220310
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. = blocking distance of
the sensor (see chapter " Technical data"); hmax.=max.llingoftherectangular
spillway
1 Overfallorice(sideview)
2 Upstream water
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 • Four-wire 4 … 20 mA/HART
30508-EN-220310
• 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
• Distance of the sensor to the max. height of damming by taking
the blocking distance into account
2
3 ... 4 x hmax
90°
hmax
d
B
1
Fig.16:FlowmeasurementwithKhafagi-Venturiume:d=Blockingdistanceto
sensor; 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
• Distance of the sensor to the max. height of damming by taking
the blocking distance into account
Flow measurement with
KhafagiVenturiume

19
5 Connecting to power supply
OPTISOUND 3020 C • Four-wire 4 … 20 mA/HART
30508-EN-220310
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.
• If overvoltage surges are expected, overvoltage arresters should
be installed.
Note:
Install a disconnecting device for the instrument which is easy to
access.The disconnecting device must be marked for the instrument
(IEC/EN 61010).
Supply voltage and current output are carried on separate two-wire
connection cables if reliable separation is required. The supply volt-
agerangecandierdependingontheinstrumentversion.
Thedataforpowersupplyarespeciedinchapter"Technical data".
The standard version can be operated with an earth-connected cur-
rentoutput,theExdversionmustbeoperatedwithaoatingoutput.
This instrument is designed in protection class I.To maintain this
protection class, it is absolutely necessary that the ground conductor
be connected to the internal ground terminal.Take note of the general
installation regulations.
Always connect the instrument to vessel ground (potential equalisa-
tion) or in case of plastic vessels to the next ground potential. For
this purpose there is a ground terminal on the side of the instrument
housing.
For voltage supply, an approved installation cable with PE conductor
is required.
The 4 … 20 mA current output is connected with standard two-wire
cable without shielding. If electromagnetic interference is expected
which is above the test values of EN 61326 for industrial areas,
shielded 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 for instruments with housing and
cablegland.Toensurethesealeectofthecablegland(IPprotection
rating),ndoutwhichcableouterdiameterthecableglandissuitable
for.
Useacableglandttingthecablediameter.
If shielded cable is required, we recommend connecting the cable
screening on both ends to ground potential. In the sensor, the cable
screening must be connected directly to the internal ground terminal.
Safety instructions
Voltage supply
Connection cable
Cable screening and
grounding

20
5 Connecting to power supply
OPTISOUND 3020 C • Four-wire 4 … 20 mA/HART
30508-EN-220310
The ground terminal on the outside of the housing must be connected
to the ground potential (low impedance).
In Ex systems, the grounding is carried out according to the installa-
tion regulations.
With the Exd version, the minus side of the signal output is galvani-
cally connected to ground via protective diodes. When connecting the
instrumenttoagroundedPLC,equalisingcurrentscanowincase
ofpotentialdierenceswhichcancausemalfunctions.Makesure
thatthereissucientpotentialequalisationfromthesystemsideor
realisetheconnectionviaswitchingamplier.
5.2 Connection procedure
Proceed as follows:
1. Unscrew the housing lid
2. Loosen compression nut of the cable gland and remove blind
plug
3. Remove approx. 10 cm (4 in) of the cable mantle (current output),
strip approx. 1 cm (0.4 in) insulation from the ends of the indi-
vidual wires
4. Insert the cable into the sensor through the cable entry
5. Lift the opening levers of the terminals with a screwdriver
6. Insert the wire ends into the open terminals according to the wir-
ing plan
Fig. 17: Connection steps 5 and 6
7. Press down the opening levers of the terminals, you will hear the
terminal spring closing