Optek 156 User manual
optek-converters C4121 and C4151
Instruction Manual
optek-converter 156
optek-Manual--1004-1022-02--156-US-2017-12-11
PN: 1004-1022-02 (-52)
optek-Danulat GmbH
Emscherbruchallee 2
45356 Essen
Germany
Phone: +49-(0)201-63409-0
E-Mail: info@optek.de
Internet: www.optek.com
Preface
optek-Manual--1004-1022-02--156-US-2017-12-11
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Preface
This instruction manual is written to assist the user in proper procedures for
trouble-free operation.
Itis explicitlypointed out thatoptek-Danulat GmbH assumes no responsibilityfor
loss or damage caused due to improper use of this instruction manual or
products described herein.
This manual is protected by copyright. However, the user may produce copies
and translations if required for correct operation of the products.
On request, this manual is available in other languages as well as in digital
format (Acrobat®Reader 7.0 required).
Our products are being continuously improved. Technical data is subject to
change without notice.
Essen, October 2016
Table of contents
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Table of contents
1 Using the instruction manual .................................................................................................1
1.1 Validity of the instruction manual......................................................................................... 1
1.2 Pictograms and signal words............................................................................................... 2
2 Returns and disposal .............................................................................................................. 3
2.1 Declaration of decontamination ........................................................................................... 3
2.2 Disposal .............................................................................................................................. 3
3 Intended use ............................................................................................................................4
4 Safety ........................................................................................................................................5
4.1 General safety instructions ..................................................................................................5
4.2 Safety instructions for works on electrical equipment .......................................................... 6
5 Description of the converter ..................................................................................................7
5.1 Converter front view ............................................................................................................ 8
5.2 Converter rear view ............................................................................................................. 9
6 Technical data ....................................................................................................................... 10
6.1 Possible sensors ............................................................................................................... 11
6.2 Converter dimensions........................................................................................................ 12
6.2.1 Dimensions for wall mount housing B19-21 - plastic (ABS) - IP66 (option) ............13
6.2.2 Dimensions for wall mount housing B19-42 - plastic (ABS) - IP66 (option) ............14
6.2.3 Dimensions for wall mount housing S19-42 -
stainless steel 1.4301/SS304 - IP65 (option) ..........................................................15
6.2.4 Dimensions for mounting with mounting angle .......................................................16
7 Installation of the converter .................................................................................................17
7.1 Installation site requirements for standard installation ....................................................... 17
7.2 Standard installation.......................................................................................................... 17
7.3 Requirements for mounting with mounting angle............................................................... 18
7.4 Mounting with mounting assembly..................................................................................... 18
8 Wiring .....................................................................................................................................19
8.1 General advice on wiring ................................................................................................... 19
8.2 Connecting the voltage supply 115 or 230 V AC................................................................ 20
8.3 Connecting the voltage supply 24 V AC / DC (option)........................................................ 20
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8.4 Connecting the sensor....................................................................................................... 21
8.4.1 Wiring plan AF56 to 156 converter .........................................................................23
8.4.2 Wiring plan AS56 to 156 converter .........................................................................24
8.5 Connecting the relay outputs............................................................................................. 25
8.6 Connecting the mA-output................................................................................................. 27
9 Commissioning .....................................................................................................................28
9.1 Requirements for commissioning....................................................................................... 28
9.2 Switching the converter on ................................................................................................ 28
9.3 Adjusting lamp voltage ...................................................................................................... 29
9.4 Setting the zero point......................................................................................................... 31
9.5 Setting the measuring range.............................................................................................. 32
9.6 Setting alarms ................................................................................................................... 35
9.7 Adjusting the digital read-out ............................................................................................. 36
9.8 Other activities when commissioning................................................................................. 37
10 Faults ......................................................................................................................................38
11 Spare parts and accessories ................................................................................................ 40
11.1 Accessories converter .......................................................................................................40
11.2 Small parts fuses............................................................................................................... 41
12 Appendix ................................................................................................................................42
12.1 Installation documentation - hardware............................................................................... 43
13 EU declaration of conformity ...............................................................................................44
14 Contacts .................................................................................................................................45
Using the instruction manual
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1 Using the instruction manual
1.1 Validity of the instruction manual
This instruction manual is valid for the optek-converter 156 only.
Follow the instruction manual for every operation. If the converter is not used as
described in this instruction manual, your safety andthe converter function could
be affected.
To keep up reliability of the product, enhance its life cycle and avoid down times,
you have to follow the instructions given in this manual.
Furthermore, please follow the existing accident prevention and environmental
protection instructions, as well as recognized technical instructions for safe and
professional working.
Using the instruction manual
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1.2 Pictograms and signal words
Especially important information in this instruction manual is marked with the
following pictograms:
Danger!
This pictogram indicates immediate danger to life and health of persons.
The text next to the symbol gives information on how to avoid bodily injuries.
If the possible cause of risk can be specified, the corresponding pictogram
preceeds instructions:
Danger!
Electrical voltage.
This pictogram indicates danger due to electrical voltage.
Caution!
This pictogram indicates information on how to avoid material damage.
Note!
This pictogram indicates instructional or general advice.
Returns and disposal
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2 Returns and disposal
2.1 Declaration of decontamination
For the safety of our employees and because of legal regulations we require a
signed "declaration of decontamination" before your return can be handled.
This signed declaration must be included with the shipping documents on the
outside of the packaging.
Any returns which were exposed to hazardous substances and were not
professionally decontaminated are not accepted and will be sent back at your
cost.
optek's declaration of decontamination and contact information can be found on
our website www.optek.com.
2.2 Disposal
Special legal regulations apply to the return and disposal of industrial waste
equipment. However, manufacturer and user can contractually agree on which
party is to fulfill these legal obligations.
Observe current national disposal regulations.
For disposing of packaging material, please separate materials:
• paper / cardboard
•plastic
For disposal, disassemble the system components and separate them
according to different material groups.
Dispose of materials according to national and local regulations.
If no agreement has been made, products may be shipped to optek for disposal.
Intended use
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3 Intended use
The converter is exclusively to be used as a converter for optek-sensor as-
semblies according to the technical data.
In connection with the inline sensors for turbidity, concentration and color, the
converter is used for displaying and processing of measuring results.
The converter is only applicable for sensors listed in the chapter "Technical da-
ta".
The converter is to be installed in a control cabinet, which provides an external
release device so that the converter can be switched voltage-free. Observe
chapter "Technical data".
The use in explosion proof areas is prohibited.
Unauthorizedconstructionalchanges, additionalfittings orrebuildings as wellas
changes to and interference with the converter program are prohibited.
The manufacturer is not liable for damage resulting from use contrary to inten-
ded use.
Following this instruction manual is part of the intended use.
The content of all serial number plates on optek products is model specific and
refers to the time of delivery.
Safety
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4Safety
4.1 General safety instructions
Only operate the converter when free from defects and in accordance with the
instructions provided in this manual.
Read this instruction manual prior to initial commissioning. This applies
especially to persons only operating the converter occasionally, such as
maintenance staff.
Observe all safety and information labels on the product and keep them in
readable condition.
Inspect the product for signs of physical damage. Report any damage
immediately and do not commission the product until corrective actions have
been taken.
After maintenance and repair, proper function as well as the fulfillment of the
safety requirements and testing must be guaranteed.
Protect the converter from impacts causing corrosion or preventing components
from working properly.
Have faulty parts of the measuring system replaced immediately.
Spare parts must comply with the technical requirements defined by optek. This
is always guaranteed when using original spare parts.
For maintenance and repair activities, attach a warning sign to the external
release device to prevent re-commissioning of the converter.
When malfunctioning, take the product out of operation. Have the malfunctions
repaired immediately by a qualified electrician.
The safety instructions are to be supplemented with the current national
regulations on accident prevention.
Safety
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4.2 Safety instructions for works on electrical equipment
Work on electrical equipment has to be carried out by qualified electricians only.
The power line connection of the converter must be specified correctly to
prevent overload.
Disconnect the voltage supply before connecting the power line. Only connect
the power line when voltage-free. Do not use the terminal socket for release
since no first-to-mate last-to-break protective ground contact is provided.
Do not work on live active parts of the electrical equipment. When working on
the electrical equipment, observe the following safety regulations:
1. Switch voltage-free.
2. Protect against re-commissioning.
3. Check if voltage-free.
4. Cover live parts.
5. Earth and short-circuit.
In case of faults in the power supply, disconnect the converter immediately.
In case of a short-circuit, there is a danger of sparking and fire.
Use only original fuses with specified current and triggering characteristics!
When a fuse has to be exchanged, first try to detect the cause and clear the fault
before exchanging the fuse.
When work on live parts is necessary, use insulated tools only.
Description of the converter
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5 Description of the converter
The converter is an universal device designed for process monitoring and con-
trol of an optek-sensor assembly.
Fig. 1 156 converter
The converter determines the change of light intensity by means of photocurrent
transmitted by the sensor. After taking the logarithm, a measurement signal
proportional to the concentration in the process medium is obtained. The 156
provides four defined and one variable measuring range to be adjusted to your
specific process parameters. The LED indicator indicates the percentage of the
selected measuring range. For connection to the process control system, the
156 converter is equipped with two independent setpoints and a
4 - 20 mA-output for alarms and real-time process monitoring. An additional
relay output (failsafe) gives alarm in case of lamp or power failure. Basic system
calibration is carried out in concentration units (CU).
The converter complies with the highest security standards. The device com-
plies with the requirements of the EMC Directive in accordance with CE.
Description of the converter
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5.1 Converter front view
Fig. 2 156 converter
Numbers stand for:
1. Digital read-out, LED display, 3 digits, height: 7 mm
2. 5 LEDs (yellow), indication of set measuring range
3. LED (red), switch indicator for alarm 2
4. Encoding button for setting alarm 2 in steps of 1 % of the respective
measuring range
5. LED (green), zero point indication
6. Encoding button for setting alarm 1 in steps of 1 % of the respective
measuring range
7. LED (red), switch indicator for alarm 1
8. LED (red), lamp failure indication
9. LED (red), power indication
10. DIP switch (RANGE 1 - 10) for measuring range setting
11. Potentiometer (VAR) for setting the variable measuring range
12. Potentiometer (ZERO) for zero point setting
13. DIP switch (DISP 5 - 6) for setting digital read-out 1
14. Potentiometer for setting digital read-out 1
15. Measuring range plate for CU
Note!
DIP switches DISP 1 - 4 (position 13 in fig. 2) only serve for factory calibration
and may not be actuated by the user.
1
2
3
4
5
6
7
8
910
11
12
13
14
15
Description of the converter
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5.2 Converter rear view
Fig. 3 Converter rear view
Numbers stand for:
16. Potentiometer for lamp voltage
17. Lamp output (only for optek-sensors)
18. mA-output (4 - 20 mA)
19. Relay output 1
20. Relay output 2
21. Relay output 3
22. Power switch
23. Selector switch for voltage (preset 230 V AC or 115 V AC) -
(does not apply for a 24 V AC / DC version)
24. Power supply (fixed)
25. Fuse I
• T 0.315 A for 230 V AC
• T 0.630 A for 115 V AC
• T 1.250 A for 24 V AC/DC
26. Fuse II
• T 0.315 A for 230 V AC
• T 0.630 A for 115 V AC
• T 1.250 A for 24 V AC/DC
27. Detector input (only for optek-sensors)
ALARM II
14
MADE IN GERMANY
OPTEK-DANULAT
N
PE
L
230V
LAMP AL
17
18
15
16
3
DETECTORINPUTS
5
5
4
50/60Hz, 30VA
230VAC, T0,315A
115VAC, T0,630A
115/230V
!
5
1
2
8
ALARM I
11
13
12
10
9
mA
VOLTAGE
6
7
LAMP
LAMP -
212019
16
19
21
18
22
17
20
23
24
25
26
27
Technical data
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6 Technical data
Tab. 1 Technical data 156 converter*
Housing: 19"-version for mounting in control cabinets 3 U / 21 HP
- dimensions: W 106.3 mm (4.19 in.) H 128.4 mm (5.06 in.) D 208 mm (8.19 in.)
- material: aluminium / diverse plastics
- protection: front IP40 / rear IP20 (mains supply secured against accidental touching)
Display: 1 digital display, 3 digits, LED, height 7mm
Operation: dip switches, potentiometer, coding switch
LED: 1 LED (red): power on
1 LED (green): zero
5 LED (yellow): measuring ranges
2 LED (red): alarm I and II
1 LED (red): lamp or system failure
Sensor-inputs: 1 for optek photometric sensor AF56 or AS56
Sensor lamp-outputs: 1 lamp supply for optek photometric sensor AF56 or AS56
4.8 ... 7.0 V DC
mA-outputs: 1 x 4 - 20 mA
functionally galvanically isolated (min. 500 V DC) for connection to PELV
- accuracy: < 1 %
- load: < 500 Ohm
Relay-outputs: 2 independently adjustable SPDT contacts
0 - 250 V AC, 0 - 300 V DC, 0 - 8 A (refer to load limit curve relay outputs in the manual)
- for alarm I and II
Failsafe-output: 1 SPDT contact to alarm in case of lamp or system failure (active)
0 - 250 V AC, 0 - 300 V DC, 0 - 8 A (refer to load limit curve relay outputs in the manual)
Cable lengths (sensor): 2, 3, 5, 10, 15, 20, 30 … 100 m
(7, 10, 16, 33, 49, 66, 98 …328 ft)
sensor AS56: max 50 m
Power supply
(Fixed, secured against acci-
dental touching):
115 / 230 V AC, selectable (93.5 - 132 / 187 - 264 V AC, 47 - 64 Hz) or
24 V AC / DC (AC: 20.4 - 26.4 V AC, 47 - 64 Hz; DC: 20.4 - 28.8 V DC) (SELV / PELV)
consider an external release device
- power consumption: < 30 VA
Ambient conditions: temperature during operation (no direct sunlight):
- converter: 0 - 50 °C (32 - 122 °F)
- with optional stainless steel housing S19-42 (IP65): 0 - 40 °C (32 - 104 °F)
- with optional plastic housing B19-42 (IP66): 0 - 35 °C (32 - 95 °F)
- with optional plastic housing B19-21 (IP66): 0 - 35 °C (32 - 95 °F)
- temperature during transport (no direct sunlight): -20 - 70 °C (-4 -158 °F)
EN 61010-1 / 2002-08 / class 1
Weights: 156 with mounting angle: 1.4 - 2.0 kg
156 with S19-42 housing: 8.5 - 7.9 kg
156 with B19-42 housing: 3.5 - 4.1 kg
156 with B19-21 housing: 1.4 - 2.0 kg
Certificates: ISO 9001:2015, GS, CE
*. Data given are subject to changes without prior notice.
Technical data
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6.1 Possible sensors
One or more of the following optek-sensors can be connected to the converter:
• AF56-N
• AF56-F
• AS56-N
• AS56-F
Connecting flameproof sensors to the converter is prohibited.
The meaning of the sensor options is described in the sensor manuals.
Technical data
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6.2.1 Dimensions for wall mount housing B19-21 - plastic (ABS) - IP66 (option)
Fig. 5 Dimensions with wall mount housing B19-21
optek
X56
ZERO
VAR
24.8
ALARM 1
LAMP
FAILURE
POWER
ALARM 2
88 88
176mm [6.93"]
192.7mm [7.59"]
206mm [8.11"]
5.5mm [0.22"]
120mm [4.72"]90mm [3.54"]
13.4mm [0.53"]
2x M20 4x M16
140°
140°
90mm [3.54"]
237mm [9.33"]
265mm [10.43"]
81mm [3.19"]
287mm [11.3"]
Technical data
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6.2.2 Dimensions for wall mount housing B19-42 - plastic (ABS) - IP66 (option)
Fig. 6 Dimensions with wall mount housing B19-42
ALARM 2ALARM 1ALARM 2ALARM 1
optekoptek
X56
ZERO
X56
ZERO
POWER
LAMP
FAILURE
24.8 24.8
LAMP
VAR
POWER
FAILURE
VAR
8888 888 8
120mm [4.72"]90mm [3.54"]
13.4mm [0.53"]
323mm [12.72"]
340mm [13.39"]
353mm [13.9"]
140°
140°
4x M20 8x M16
Ø5.5mm [0.22"]
90mm [3.54"]
237mm [9.33"]
265mm [10.43"]
81mm [3.19"]
287mm [11.3"]
Technical data
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6.2.3 Dimensions for wall mount housing S19-42 - stainless steel 1.4301/SS304 -
IP65 (option)
Fig. 7 Dimensions with wall mount housing S19-42 - stainless steel 1.4301 / SS304 - IP65
8 8 8 8 88 88
237mm [9.33"]
265mm [10.43"]
190mm [7.48"]
323mm [12.72"]
340mm [13.39"]
353mm [13.9"]
23.5mm [0.93"]
6.4mm [0.25"]
65mm [2.56"]
271mm [10.67"]
301mm [11.85"]
295mm [11.61"]
125°
125°
4x M20
10x M16
ALARM 2
optek
ALARM 2
optek
FAILURE
X56
ALARM 1
POWER
LAMP
24.8
LAMP
FAILURE
POWER
ZERO
VAR
X56
ALARM 1
24.8
ZERO
VAR
Technical data
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6.2.4 Dimensions for mounting with mounting angle
Fig. 8 Dimensions for mounting with mounting angle W19
max. 111mm [max. 4.37"]
max. 298mm [max. 11.73"]
min. 34mm [min. 1.34"]
min. 221mm [min. 8.7"]
92mm [3.62"]
203mm [7.99"]
60mm [2.36"]
80mm [3.15"]
100mm [3.94"]
6.5mm [0.26"]
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