KROHNE OPTISOUND 3030 C User manual

OPTISOUND 3030 C Handbook
Ultrasonic Level Transmitter
4 … 20 mA/HART - two-wire

2
Contents
OPTISOUND 3030 C • 4 … 20 mA/HART - two-wire
30511-EN-150903
Contents
1 About this document
1.1 Function ........................................................................................................................... 4
1.2 Target group ..................................................................................................................... 4
1.3 Symbols used................................................................................................................... 4
2 For your safety
2.1 Authorised personnel ....................................................................................................... 5
2.2 Appropriate use................................................................................................................ 5
2.3 Warning about incorrect use............................................................................................. 5
2.4 General safety instructions............................................................................................... 5
2.5 Safety label on the instrument .......................................................................................... 6
2.6 CE conformity................................................................................................................... 6
2.7 FulllmentofNAMURrecommendations ......................................................................... 6
3 Product description
3.1 Conguration.................................................................................................................... 7
3.2 Principle of operation........................................................................................................ 8
3.3 Packaging, transport and storage..................................................................................... 8
4 Mounting
4.1 General instructions ....................................................................................................... 10
4.2 Mountinginstructions ..................................................................................................... 11
5 Connecting to power supply
5.1 Preparing the connection ............................................................................................... 18
5.2 Connection procedure.................................................................................................... 19
5.3 Wiring plan, single chamber housing.............................................................................. 20
5.4 Wiring plan, double chamber housing ............................................................................ 22
5.5 Switch-on phase............................................................................................................. 23
6 Set up with the display and adjustment module
6.1 Insert display and adjustment module............................................................................ 24
6.2 Adjustment system......................................................................................................... 25
6.3 Setup steps .................................................................................................................... 26
6.4 Menuschematic............................................................................................................. 37
6.9 Saving the parameter adjustment data........................................................................... 39
7 Maintenanceandfaultrectication
7.1 Maintenance .................................................................................................................. 40
7.2 Rectify faults................................................................................................................... 40
7.3 Exchanging the electronics module................................................................................ 41
7.4 Instrument repair ............................................................................................................ 41
8 Dismount
8.1 Dismounting steps.......................................................................................................... 42
8.2 Disposal ......................................................................................................................... 42
9 Supplement
9.1 Technical data ................................................................................................................ 43
9.2 Dimensions .................................................................................................................... 46

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Contents
OPTISOUND 3030 C • 4 … 20 mA/HART - two-wire
30511-EN-150903
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 manual.
Editing status: 2015-08-18

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1 About this document
OPTISOUND 3030 C • 4 … 20 mA/HART - two-wire
30511-EN-150903
1 About this document
1.1 Function
This operating instructions manual provides all the information you
need for mounting, connection and setup as well as important instruc-
tionsformaintenanceandfaultrectication.Pleasereadthisinforma-
tion before putting the instrument into operation and keep this manual
accessible in the immediate vicinity of the device.
1.2 Target group
This operating instructions manual is directed to trained specialist
personnel. The contents of this manual should be made available to
these personnel and put into practice by them.
1.3 Symbols used
Information, tip, note
This symbol indicates helpful additional information.
Caution: If this warning is ignored, faults or malfunctions can result.
Warning: If this warning is ignored, injury to persons and/or serious
damage to the instrument can result.
Danger: If this warning is ignored, serious injury to persons and/or
destruction of the instrument can result.
Ex applications
This symbol indicates special instructions for Ex applications.
SIL applications
This symbol indicates instructions for functional safety which must be
taken into account particularly for safety-relevant applications.
• List
The dot set in front indicates a list with no implied sequence.
→ Action
This arrow indicates a single action.
1 Sequence of actions
Numbers set in front indicate successive steps in a procedure.
Battery disposal
This symbol indicates special information about the disposal of bat-
teries and accumulators.

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2 For your safety
OPTISOUND 3030 C • 4 … 20 mA/HART - two-wire
30511-EN-150903
2 For your safety
2.1 Authorised personnel
All operations described in this operating instructions manual must
be carried out only by trained specialist personnel authorised by the
plant operator.
During work on and with the device the required personal protective
equipment must always be worn.
2.2 Appropriate use
OPTISOUND 3030 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.
For safety and warranty reasons, any invasive work on the device
beyond that described in the operating instructions manual may be
carried out only by personnel authorised by the manufacturer. Arbi-
traryconversionsormodicationsareexplicitlyforbidden.
2.3 Warning about incorrect use
Inappropriate or incorrect use of the instrument can give rise to
application-specichazards,e.g.vesseloverllordamagetosystem
components through incorrect mounting or adjustment.
2.4 General safety instructions
This is a state-of-the-art instrument complying with all prevailing
regulations and guidelines.The instrument must only be operated in a
technicallyawlessandreliablecondition.Theoperatorisresponsible
for the trouble-free operation of the instrument.
During the entire duration of use, the user is obliged to determine the
compliance of the necessary occupational safety measures with the
current valid rules and regulations and also take note of new regula-
tions.
The safety instructions in this operating instructions manual, the na-
tional installation standards as well as the valid safety regulations and
accident prevention rules must be observed by the user.
For safety and warranty reasons, any invasive work on the device
beyond that described in the operating instructions manual may be
carried out only by personnel authorised by the manufacturer. Arbi-
traryconversionsormodicationsareexplicitlyforbidden.
The safety approval markings and safety tips on the device must also
be observed.

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2 For your safety
OPTISOUND 3030 C • 4 … 20 mA/HART - two-wire
30511-EN-150903
2.5 Safety label on the instrument
The safety approval markings and safety tips on the device must be
observed.
2.6 CE conformity
ThedevicefulllsthelegalrequirementsoftheapplicableECguide-
lines.ByaxingtheCEmarking,weconrmsuccessfultestingofthe
product.
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llstherequirementsofthefollowingNAMURrecom-
mendations:
• NE 21 – Electromagnetic compatibility of equipment
• NE53–Compatibilityofelddevicesanddisplay/adjustment
components
For further information see www.namur.de.

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3 Product description
OPTISOUND 3030 C • 4 … 20 mA/HART - two-wire
30511-EN-150903
3 Product description
3.1 Conguration
The scope of delivery encompasses:
• OPTISOUND 3030 C ultrasonic sensor
• Optionallymountingstraporcompressionange
• Documentation
– This operating instructions manual
– Ex-specicsafetyinstructions(withExversions)
– Operating instructions manual "Display and adjustment mod-
ule"(optional)
– ifnecessary,furthercerticates
Information:
In this operating instructions manual, the optional instrument features
are described. The respective scope of delivery results from the order
specication.
The OPTISOUND 3030 C consists of the components:
• Processttingwithtransducer
• Housing with electronics
• Housing cover with integrated display and adjustment module
(optional)
Thecomponentsareavailableindierentversions.
1
2
3
Fig. 1: OPTISOUND 3030 C with plastic housing
1 Housing cover 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
• Article numbers, documentation
Scope of delivery
Constituent parts
Type label

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3 Product description
OPTISOUND 3030 C • 4 … 20 mA/HART - two-wire
30511-EN-150903
• Technical data: For example approvals, process temperature,
processtting/material,signaloutput,powersupply,protection
3.2 Principle of operation
OPTISOUND 3030 C is an ultrasonic sensor for continuous level
measurement. It is suitable for liquids and solids in practically all
industries.
The transducer of the ultrasonic sensor transmits short ultrasonic
pulsestothemeasuredproduct.Thesepulsesarereectedby
product 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.
4 … 20 mA/HART two-wire electronics for voltage supply and meas-
ured value transmission on the same cable.
Thesupplyvoltagerangecandierdependingontheinstrumentver-
sion. The exact range is stated in chapter "Technical data".
The backlight of the display and adjustment module is powered by
the sensor. The prerequisite for this is a supply voltage at a certain
level.Theexactvoltagespecicationsarestated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.
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

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3 Product description
OPTISOUND 3030 C • 4 … 20 mA/HART - two-wire
30511-EN-150903
• Protected against solar radiation
• Avoiding mechanical shock and vibration
• Storage and transport temperature see chapter "Supplement -
Technical data - Ambient conditions"
• Relative humidity 20 … 85 %
Storage and transport
temperature

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4Mounting
OPTISOUND 3030 C • 4 … 20 mA/HART - two-wire
30511-EN-150903
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 OPTISOUND 3030 C additional protection against
moisture penetration by leading the connection cable downward in
front of the cable entry. Rain and condensation water can thus drain
o.Thisappliesmainlytooutdoormountingaswellasinstallationin
areaswherehighhumidityisexpected(e.g.throughcleaningpro-
cesses)oroncooledorheatedvessels.
Fig. 2: Measures against moisture ingress
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
maintained.Theexactvalueofthedeadzoneisstatedinchapter
"Technical data".
Installation position
Moisture
Cableentries-NPT
thread
Measuring range

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4Mounting
OPTISOUND 3030 C • 4 … 20 mA/HART - two-wire
30511-EN-150903
1
2
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3030
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).
4.2 Mounting instructions
When mounting the OPTISOUND 3030 C, 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").
Pressure/Vacuum
Installation position

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4Mounting
OPTISOUND 3030 C • 4 … 20 mA/HART - two-wire
30511-EN-150903
If this distance cannot be maintained, a false signal storage should
be carried out during setup. This applies particularly if buildup on the
vessel wall is expected. In such cases, we recommend repeating the
false signal storage at a later date with existing buildup.
12
> 200 mm
Fig. 5: Mounting on round vessel tops
1 Reference plane
2 Vessel center or symmetry axis
In vessels with conical bottom it can be advantageous to mount the
sensor in the center of the vessel, as measurement is then possible
down to the lowest point of the vessel bottom.
Fig. 6: Vessel with conical bottom
Preferablythetransducershouldbemountedushtothevesseltop.
Ifthereectivepropertiesofthemediumaregood,youcanmount
OPTISOUND3030Conasocketpiece.Youwillndrecommended
values for socket heights in the following illustration. The socket end
Socket

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4Mounting
OPTISOUND 3030 C • 4 … 20 mA/HART - two-wire
30511-EN-150903
should be smooth and burr-free, if possible also rounded. Carry out a
false echo storage.
d
45°
hmax.
d
100 mm/4"
150 mm/6"
200 mm/8"
250 mm/10"
300 mm
400 mm
500 mm
600 mm
hmax.
Fig. 7: Deviating socket dimensions
In liquids, direct the sensor as perpendicular as possible to the prod-
uct surface to achieve optimum measurement results.
Fig. 8: Alignment in liquids
To optimally align the sensor to solid products, a swivelling holder
(mountingstrap)canbeimplemented.
Sensor orientation

14
4Mounting
OPTISOUND 3030 C • 4 … 20 mA/HART - two-wire
30511-EN-150903
Fig. 9: Orientation in solids
To reduce the min. distance to the medium, you can also mount OP-
TISOUND3030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 echo storage should be
carried out during setup.
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.
Vessel installations

15
4Mounting
OPTISOUND 3030 C • 4 … 20 mA/HART - two-wire
30511-EN-150903
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 storage should be
carried out with the agitators in motion. This ensures that the interfer-
ing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 3030 C • 4 … 20 mA/HART - two-wire
30511-EN-150903
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 product 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3030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 3030 C • 4 … 20 mA/HART - two-wire
30511-EN-150903
max.
min.
1
Fig. 14: Standpipe in the tank
1 Vent hole ø 5 … 10 mm
OPTISOUND 3030 C can be used from tube diameters of 100 mm.
Avoid large gaps and thick welding joints when connecting the tubes.
Generally carry out a false echo storage.
Measurementinastandpipeisnotrecommendedforextremely
adhesive products.

18
5 Connecting to power supply
OPTISOUND 3030 C • 4 … 20 mA/HART - two-wire
30511-EN-150903
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
personnel authorised by the plant operator.
• If overvoltage surges are expected, overvoltage arresters should
be installed.
Power supply and current signal are carried on the same two-wire
cable.Theoperatingvoltagecandierdependingontheinstrument
version.
Thedataforpowersupplyarespeciedinchapter"Technical data".
Provide a reliable separation between the supply circuit and the
mains circuits according to DIN EN 61140 VDE 0140-1.
Keepinmindthefollowingadditionalfactorsthatinuencetheoperat-
ing voltage:
• Lower output voltage of the power supply unit under nominal load
(e.g.withasensorcurrentof20.5mAor22mAincaseoffault)
• Inuenceofadditionalinstrumentsinthecircuit(seeloadvaluesin
chapter "Technical data")
The instrument is connected with standard two-wire cable without
screen. If electromagnetic interference is expected which is above the
test values of EN 61326-1 for industrial areas, screened cable should
be used.
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.
We generally recommend the use of screened cable for HART multi-
drop mode.
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.
If screened cable is required, we recommend connecting the cable
screen on both ends to ground potential. In the sensor, the screen
Safety instructions
Voltage supply
Connection cable
Cablegland½NPT
Cable screening and
grounding

19
5 Connecting to power supply
OPTISOUND 3030 C • 4 … 20 mA/HART - two-wire
30511-EN-150903
must be connected directly to the internal ground terminal.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.
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 slightly to the left.
3. Loosen compression nut of the cable entry gland
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
8. Press down the opening levers of the terminals, you will hear the
terminal spring closing
9. Check the hold of the wires in the terminals by lightly pulling on
them
10. Connect the screen to the internal ground terminal, connect the
outer ground terminal to potential equalisation
11. Tighten the compression nut of the cable entry gland. The seal
ring must completely encircle the cable
12. Screw the housing lid back on
Theelectricalconnectionisnished.

20
5 Connecting to power supply
OPTISOUND 3030 C • 4 … 20 mA/HART - two-wire
30511-EN-150903
Fig. 15: Connection steps 6 and 7
5.3 Wiring plan, single chamber housing
1
4
44
2 3
Fig.16:Materialversions,singlechamberhousing
1 Plastic
2 Aluminium
3 Stainless steel
4 Filter element for air pressure compensation
Housing overview