Operating Instructions - OPTISWITCH 3200 C with two
Contents
1. Fig 13 Loosen the screws 1 Electronics module 2 Screws 2 pcs 6 Remove the old oscillator OPTISWITCH 3200 C with two wire output 25 Maintenance and fault rectification 26 Ae 7 Compare the new oscillator with the old one The type label of the oscillator must correspond to that of the old oscillator This applies particularly to instruments used in hazardous areas 8 Compare the settings of the two oscillators Set the adjustment elements of the new oscillator to the settings of the old oscillator Information Make sure that the housing is not rotated during the electronics exchange Otherwise the plug may be in a different position later 9 Insert the oscillator carefully Make sure that the plug is in the correct position 10 Screw in and tighten the two screws with a Phillips screwdriver 11 Insert the wire ends into the open terminals according to the wiring plan 12 Close the opening levers of the terminals you will hear the terminal spring closing 13 Check the hold of the wires in the terminals by lightly pulling on them 14 Check the tightness of the cable entry The seal ring must completely encircle the cable 15 Screw the housing cover back on The electronics exchange is finished 7 4 Instrument repair If a repair is necessary please proceed as follows You can download a return form from our Internet homepage http www krohne mar com fileadmin media lounge PDF Downloa2. Solid detection in water If OPTISWITCH 3200 C was ordered for solids detection in water the tuning fork is set to the density of water In air or when immersed in water density 1 g cm 0 036 Ibs in OPTISWITCH 3200 C signals uncovered Only when the vibrating element is also covered with solids e g sand sludge gravel etc will the sensor signal covered Fault monitoring The electronics of OPTISWITCH 3200 C continuously mon itors the following criteria e Correct vibrating frequency e Line break to the piezo drive If one of these faults is detected the electronics signals it via a defined current to the signal conditioning instrument The connection cable to the vibrating element is also monitored The tuning fork is piezoelectrically energised and vibrates at its mechanical resonance frequency of approx 150 Hz When the tuning fork is submerged in the product the vibration amplitude changes This change is detected by the integrated oscillator and converted into a switching command Depending on your requirements OPTISWITCH 3200 C with two wire electronics can be connected to different signal conditioning instruments Compatible signal conditioning in struments are listed under Technical data The exact range of the voltage supply is specified in the Technical data in the Supplement 3 3 Adjustment 3 With the factory setting products with a density of gt 0 02 g cm gt 0 0008 Ibs in can be measured
3. 29959 EN 060112 KROHNE Comestngtopowersuppy 3 Remove approx 10 cm 4 in of the cable mantle strip approx 1 cm 0 4 in insulation from the ends of the individual wires 4 Insert the cable into the sensor through the cable entry 5 Lift the opening levers of the terminals with a screwdriver see following illustration 6 Insert the wire ends into the open terminals according to the wiring plan 7 Press down the opening levers of the terminals you will hear the terminal spring closing 8 Check the hold of the wires in the terminals by lightly pulling on them 9 Tighten the compression nut of the cable entry the seal ring must completely encircle the cable 10 Screw the housing cover back on The electrical connection is finished Fig 8 Connection steps 5 and 6 5 3 Wiring plans single chamber housing The following illustrations apply to the non Ex as well as to the Ex EEx d version OPTISWITCH 3200 C with two wire output 17 Connecting to power supply Housing overview Electronics and connection compartment Wiring plan 18 Fig 9 Material versions single chamber housing Plastic not with EEx d Aluminium Stainless steel not with EEx d Filter element for pressure compensation not with EEx d KON A Fig 10 Electronics and connection compartment Potentiometer for switching point adaptation covered DIL switch for mode adjustment Grou
4. 1 2 4 Functional safety of electrical electronic programmable electronic systems The failure limit values for a safety function depending on the SIL class of IEC 61508 1 7 6 2 Safety integrity level Low demand mode High demand mode gt 10 up to lt 10 gt 10 up to lt 10 gt 10 up to lt 107 gt 10 up to lt 10 PR gt 107 up to lt 10 gt 10 up to lt 107 gt 10 up to lt 10 gt 10 up to lt 10 OPTISWITCH 3200 C with two wire output GL LO90 NA 6S66 e 29959 EN 060112 General instructions and re strictions Assumptions Functional safety Safety integrity of the hardware for safety related subsystems of type B IEC 61508 2 7 4 3 Safe failure fraction Hardware fault toler ance 60 up to lt 90 90 up to lt 99 9 2 Planning e The measuring system must be used acc to the application e The application specific limits must be maintained and the specifications not exceeded e Acc to the specifications in the operating instructions manual the current load of the output circuits must be within the limits e It must be used only in products to which the materials of the vibrating system are sufficiently chemically resistant Note the following items for use as dry run protection system e Avoid buildup on the vibrating system possibly smaller proof test intervals e Avoid granulation size of the product gt 15 mm For the implementation o
5. It is possible to adapt the instrument for products with lower density gt 0 008 g cm gt 0 0003 Ibs in OPTISWITCH 3200 C with two wire output col LO90 N3A 6S66 2 29959 EN 060112 Packaging Storage and transport tem perature Product description On the electronics module you will find the following indicating and adjustment elements e signal lamp for indication of the switching condition green red e potentiometer for adaptation to the product density e mode switch for selection of the output current 3 4 Storage and transport Your instrument was protected by packaging during transport Its capacity to handle normal loads during transport is assured by a test acc to DIN 55439 The packaging of standard instruments consists of environ ment friendly recyclable cardboard In addition the sensor is provided with a protective cover of cardboard For special versions PE foam or PE foil is also used Dispose of the packaging material via specialised recycling companies e Storage and transport temperature see Supplement Technical data Ambient conditions e Relative humidity 20 85 OPTISWITCH 3200 C with two wire output 9 Mounting Switching point Moisture Transport Pressure Vacuum Handling 10 4 Mounting 4 1 General instructions In general OPTISWITCH 3200 C can be mounted in any position The instrument must be mounted in such a way that the vibrating element is at the h
6. instrument was judged by a person meeting the requirements acc to DIN EN 60078 14 Krohne SAS Romans Cedex den 31 05 05 Wro Fenk iW Stengele Fig 19 Manufacturer declaration OPTISWITCH 3200 C with two wire output Supplement 45 Supplement 46 OPTISWITCH 3200 C with two wire output col LO90 N3A 6S66 2 29959 EN 060112 OPTISWITCH 3200 C with two wire output Supplement 47 Subject to change without notice 29959 EN 060112
7. is set to max PFDavg Tproof 1 year lt 0 019 x 10 Tproot 5 years lt 0 093 x 107 Tproor 10 years lt 0 186 x 107 PFH 1 h lt 4 3 x 10 h Mode switch is set to min OPTISWITCH 3200 C with two wire output 35 Functional safety Architecture 1002D Overfill protection Architecture 1002D Dry run protection 36 PFDavg Tproot 1 year lt 0 016 x 107 Tproot 5 years lt 0 081 x 10 Tproor 10 years lt 0 162 x 107 PFH 1 h lt 3 7 x 10 h Double channel architecture Here you see an example how the measuring system in double channel architecture can be used in an application with demand rate SIL3 A Common Cause Factor of beta 10 worst case is taken into account If the instruments are used in another multiple channel architecture the values must be calculated for the selected application by means of the above failure rates SIL3 Safety Integrity Level HFT 1 Hardware Fault Tolerance Mode switch is set to max PFDavg Tproor 1 year lt 0 007 x 10 Tproot 5 years lt 0 036 x 10 Tproor 10 years lt 0 073 x 10 PFH 1 h lt 1 8 x 10 h Mode switch is set to min PED Tproor 1 year lt 0 015 x 10 Tproot 5 years lt 0 076 x 10 Tproo 10 years lt 0 153 x 10 PFH 1 h lt 2 0 x 10 h SIL3 Safety Integrity Level HFT 1 Hardware Fault Tolerance Mode switch is set to max PFDavg Tproo
8. related characteristics as well as the instructions of the safety manual must be considered see corresponding operating instruction chapter Functional Safety conviennent une utilisation dans les syst mes de s curit instrument s suivant la norme IEC 61508 Les caract nstiques techniques relatives a la s curit ainsi que les consignes de s curit stipul es dans le Safety Manual sont 4 respecter voir la notice technique de mise en service au chapitre _S curite fonctionnelle Romans 21 10 2005 KROHNE GAS Ga Ar Dr Florian Stengele Geschaftsfihrer Managing Director Directeur g n ral Fig 17 SIL declaration of conformity OPTISWITCH 3200 C with two wire output 43 Supplement CE declaration of conformity CE Konformit tserkl rung Declaration of conformity D claration de conformit KROHNE Krohne 5 4 5 Les irs HE UH F 26105 Romans Cedex erkl rt in alleiniger Verantwortung dali das Produkt declare under our sole responsibility that our product d clare sous sa seule responsabilit que le produit OPTISWITCH 3100 C OPTISWITCH 3200 C OPTISWITCH 3300 C mit Relaisausgang with relay output avec sortie relais VB60R mit Transistorausgang with transistor output avec sortie transistor VB60T mit Zweileiterausgang with two wire output avec sortie bifilaire VB602 auf das sich diese Erklarung bezieht mit den folgenden Normen bereinstimmt to which this decl
9. 7 2 Fault rectficeation 0 0006 25 7 3 Exchanging the electronics 26 7 4 Instrument repair 0008 27 8 Dismounting 8 1 Dismounting steps 28 8 2 Disposal 0 ee ee 28 OPTISWITCH 3200 C with two wire output col LO90 NA 6S66 2 29959 EN 060112 Contents 9 Functional safety EE RR ee e A E sacs 29 9 2 Planning 30 93 SCD as baa owe EE Geo oS ae SR 33 9 4 Reaction during operation and in case of failure 33 9 5 Recurring function fest 33 9 6 Safety related characteristics 34 10 Supplement 10 1 Technical data 39 10 2 Dimensions EES SE SS cee ee eee 42 10 3 Certificates ii uie sog ES LEEG ow EE ow ee 44 Supplementary operating instructions manuals Information OPTISWITCH 3200 C is available in different versions Depending on the selected version supplementary operating instructions manuals will also be included in the delivery The supplementary operating instructions manuals are listed in section Product description Operating instructions manuals for accessories and replacement parts Tip To ensure reliable use and operation of your OPTISWITCH 3200 C we offer accessories and replacement parts The corresponding operating instructions manuals are e Operating instructions manual Oscillator e Operating instructions manual Cable shortening set OPTISWITCH 3200 C with two wire output 3 About this document Pme d 1 About this document 1 1 Functio
10. C 4 176 F gt 0 02 g cm gt 0 0007 Ibs in gt 0 008 g cm gt 0 0003 Ibs iNS e 1xcable entry M20x1 5 cable g 5 9 mm 1x blind plug M20x1 5 or e 1x closing cap NPT 1x blind plug NPT Or e 1x plug depending on the version 1x blind plug M20x1 5 for wire cross section up to 1 5 mm 0 0023 in min detection or dry run protection max detection or overfill protection 10 36 V DC via the signal conditioning instrument 8 Depending on the version M12x1 acc to DIN 43650 Harting Amphenol Tuchel 7 8 FF OPTISWITCH 3200 C with two wire output 39 Supplement Electrical protective measures Protection IP 66 IP 67 Overvoltage category III Protection class II Approvals ATEX II 1G 1 2G 2G EEx ia IIC T65 ATEX II 1G 1 2G 2G EEx ia IIC T6 ATEX II 1 2 D IP66 T ATEX II 1 2G 2G EEx d IIC T6 ATEX II 1 2 D IP66 T 4 Deviating data with Ex applications see separate safety instructions 5 only in conjunction with electronics Z 6 See temperature statements in the safety instructions manual 40 OPTISWITCH 3200 C with two wire output GL LO90 N3A 6S662 Supplement 10 2 Dimensions OPTISWITCH 3200 C 69mm 116mm 69mm 2 23 32 4 916 2 23 32 77mm o 84mm 3 5 16 3 1 32 4 13 32 4 39 64 4 31 64 M20x1 5 Ye NPT M20x1 5 Yo NPT Fig 15 Housing versions 1 Plastic h
11. ITCH 3200 C is available in chapter Product description 2 3 Warning about misuse Inappropriate or incorrect use of the instrument can give rise to application specific hazards e g vessel overfill or damage to system components through incorrect mounting or adjustment 2 4 General safety instructions OPTISWITCH 3200 C is a high tech instrument requiring the strict observance of standard regulations and guidelines The user must take note of the safety instructions in this operating instructions manual the country specific installation standards e g the VDE regulations in Germany as well as all prevailing safety regulations and accident prevention rules 2 5 CE conformity OPTISWITCH 3200 C is in CE conformity with EMC 89 336 EWG fulfils the NAMUR recommendation NE 21 and is in CE conformity with NSR 73 23 EWG Conformity has been judged acc to the following standards e EMC Emission EN 61326 1997 class B Susceptibility EN 61326 1997 A1 1998 e LVD EN 61010 1 2001 OPTISWITCH 3200 C with two wire output 5 For your safety 2 6 SIL conformity OPTISWITCH 3200 C fulfills the requirements for functional safety acc to IEC 61508 You will find further information in chapter Functional safety 2 7 Safety information for Ex areas Please note the Ex specific safety information for installation and operation in Ex areas These safety instructions are part of the operating instructions manual and
12. Mount OPTI SWITCH 3200 C at a location in the vessel where no disturbing influence from e g filling openings agitators etc can occur OPTISWITCH 3200 C with two wire output col LO90 N3A 6S66 2 29959 EN 060112 Flow Mounting Fig 5 Inflowing material To minimise flow resistance caused by the tuning fork OPTISWITCH 3200 C should be mounted in such a way that the surfaces of the fork are parallel to the product movement OPTISWITCH 3200 C with two wire output 13 Mounting Baffle protection against fall ing rocks 14 Fig 6 Orientation of the tuning fork in case of flow 1 Marking with screwed version 2 Direction of flow In applications such as grit chambers or settling basins for coarse sediments the vibrating element must be protected against damage with a suitable baffle OPTISWITCH 3200 C with two wire output col LO90 N3A 6S66 2 29959 EN 060112 Mounting Fig 7 Baffle protection against damages OPTISWITCH 3200 C with two wire output 15 Connecting to power supply Note safety instructions Take note of safety instructions for Ex applications Select power supply 2 Select connection cable Select connection cable for Ex applica tions 16 2 5 Connecting to power supply 5 1 Preparing the connection Always observe the following safety instructions e Connect only in the complete absence of line voltag
13. Operating Instructions OPTISWITCH 3200 C with two wire output Variable area flowmeters Vortex flowmeters Flow controllers Electromagnetic flowmeters Ultrasonic flowmeters Mass flowmeters Level measuring instruments Communications engineering Engineering systems amp solutions Switches counters displays and recorders Heat metering Pressure and temperature Contents Contents 1 About this document 11 FUNCION se eet oe OE ee dn ee wie eee 5 12 Target group 0 2 eee 5 13 Symbolism use 5 2 For your safety 2 1 Authorised personnel 6 2 2 Appropriate use naaa aaaea 6 23 Warning about misuse 6 2 4 General safety instructions 6 2 5 CE conformity naaa anaa aeaa 6 2 6 SIL conformity a na aaa aaa 7 2 7 Safety information for Ex areas 7 3 Product description 3 1 Configuration EES SS SE Se See 8 3 2 Principle of operation 8 3 3 Adjustment SES SS ee eee 9 3 4 Storage and transport 10 4 Mounting 4 1 General instructions 05 11 4 2 Mounting information 46 12 5 Connecting to power supply 5 1 Preparing the connection 17 5 2 Connection procedure 05 17 5 3 Wiring plans single chamber housing 18 6 Setup 6 1 General 21 6 2 Adjustment elements 0 22 6 3 Function chat 23 7 Maintenance and fault rectification 7 1 Maintenance 25
14. a signal conditioning instrument always set the mode switch 2 on OPTISWITCH 3200 C to max mode The mode is selected on the signal conditioning instrument with the mode switch The switching output will change if you set one of the two mode switches afterwards This could possibly trigger other con nected instruments or devices OPTISWITCH 3200 C with two wire output col LO90 N3A 6S66 2 29959 EN 060112 Switching point adaptation 1 Mode adjustment 2 Setup 6 2 Adjustment elements WEES E a Fig 12 Oscillator VB 60Z Two wire output Potentiometer for switching point adaptation DIL switch for mode adjustment Ground terminal Terminals Control lamp OA DYH A With the potentiometer you can adapt the switching point to the solid It is already factory preset and must be adjusted only in special cases By default the potentiometer of OPTISWITCH 3200 C is set to mid position gt 0 02 g cm or gt 0 0008 Ibs in In case of very light weight solids you have to turn the potentiometer to the complete left position gt 0 008 g cm or gt 0 0003 Ibs in Hence the OPTISWITCH 3200 C will be more sensitive and can detect light weight solids more reliably For instruments detecting solids in water these values are not applicable The potentiometer is preset and must not be changed With the mode adjustment min max you can determine the output current Whe
15. aration relates is in conformity with the following standards auquel se r f re cette d claration est conforme aux normes Emission Emission Emission EN 61326 1997 Klasse B Immission Susceptibility lImmission EN 61326 1997 A1 1998 EN 61010 1 2001 gemak den Bestimmungen der Richtlinien following the provision of Directives conformement aux dispositions des Directives 74 24 EWG 89 336 EWG 7 i I de c ay 07 07 2004 PON Ga CBee LN ppo P O Florian Siengele Fig 18 CE declaration of conformity 40 OPTISWITCH 3200 C with two wire output colt LO90 N3A 6S66 2 29959 EN 060112 Manufacturer declaration Manufacturer declaration ma 24653 Messrs Krohne SAS Las Ors BP 98 F 26103 Romans Cedex declares that the Compact vibrating level switch from types OPTISWITCH 3000 C 3100 C 3200 C 3300 C with two wire output in accordance with DIN EN 60078 14 2004 paragraph 5 2 3 item c 1 and when used comectly under the condition that the operator follows the instructions in the documents listed Mounting and operating instructions in the Operating instructions manual Data and instruchons of this manufacturer declaration Installation regulations are suitable for use in Zone 2 The max surface temperature increase during operation is 40K With an ambient temperature of 70 C on the housing and a process temperature of 70 C the max surface temperature is 110 C during oper
16. ation Measures lo maintain the explosion protection during operation This declaration is only applicable if OP TISWITCH is operated within the stated electrical threshold values Permissible operating voltages 10 208 DC via the signal conditioning instrument The instrument must be installed and operated in such a way that no danger of ignition is expected due to electrostatic charge depending of the version the process fitting the plastic coated probe part or the housing are made of electrically non conductive plastic The availability the periect quality and the corect positon of the seal between the lower part of the housing and the cover must be ensured the cover must be scrawed on tightly Ifthe instrument is operated with open cover or if the switchipotentiometer is used make sure thal there is no explosive almosphere Make sure that the cable entry is tight and strain relieved the outer diameter of the connection cable must be adapted to the cable entry the pressure screw of the cable entry must be tightened carefully Free openings for cable and cable entries must be covered tightly OPTISWITCH must be mounted in such a way that contact of the sensor to the vessel wall can be excluded by taking vessel installations and flow conditions in the vessel into account The surface temperature must not exceed the ignition temperature of the concemed explosive atmosphere Single component in the instrument This
17. ble tensile load Sensor length Output variable Output Suitable signal conditioning instrument Output signal min mode max mode Fault signal 38 316L 316L Klingersil C 4400 CR CSM 316L PUR plastic PBT Polyester Alu die casting pow der coated 316L NBR stainless steel housing silicone Alu plastic housing 316L 1500 g 53 oz 1950 g 69 oz 2300 g 81 oz 165 g m 1 8 oz ft 3000 N 675 Ibs 0 3 80 m 1 262 ft Two wire output SU 501 Ex Vibrating element uncovered 16 mA 1 mA Vibrating element covered 8 mA 1 mA Vibrating element uncovered 8 mA 1 mA Vibrating element covered 16 mA 1 mA lt 2 3 MA OPTISWITCH 3200 C with two wire output col LO90 NA 6S662 29959 EN 060112 Modes adjustable Integration time when immersed when laid bare Ambient conditions Ambient temperature on the housing Storage and transport temperature Process conditions Parameter Process pressure OPTISWITCH 3200 C of 316L Density Standard adjustable Electromechanical data Cable entry plug Single chamber housing Spring loaded terminals Adjustment elements Mode switch min max Voltage supply Voltage supply Supplement min max approx 0 5 s approx 1s 40 80 C 40 40 80 C 40 176 F 176 F level of solids 1 6 bar 100 600 kPa 14 5 87 psi 20 80
18. come with the Ex approved instruments OPTISWITCH 3200 C with two wire output col LO90 N3A 6S66 2 29959 EN 060112 3 Product description 3 1 Configuration Scope of delivery The scope of delivery encompasses e OPTISWITCH 3200 C level sensor e Documentation this operating instructions manual Supplementary instructions manual Plug connector for level sensors optional Ex specific safety instructions with Ex versions if necessary further certificates Components OPTISWITCH 3200 C consists of the following components e Housing cover e Housing with electronics e process fitting with tuning fork 0 OYO 9 1 Fig 1 OPTISWITCH 3200 C with plastic housing 1 Housing cover 2 Housing with electronics 3 Process fitting 3 2 Principle of operation Area of application OPTISWITCH 3200 C is a level sensor with tuning fork for level detection OPTISWITCH 3200 C with two wire output 7 Product description Physical principle Power supply It is designed for industrial use in all areas of process technology and is preferably used for bulk solids Typical applications are overfill and dry run protection Thanks to its simple and robust measuring system OPTISWITCH 3200 C is virtually unaffected by the chemical and physical properties of the solid It functions even when exposed to strong external vibration or changing products
19. d Specimen_e pdf By doing this you help us carry out the repair quickly and without having to call for additional information e Print and fill out one form per instrument e Clean the instrument and pack it damage proof e Attach the completed form and possibly also a safety data sheet to the instrument OPTISWITCH 3200 C with two wire output col LO90 NA 6S66 2 29959 EN 060112 Dismounting 8 Dismounting 8 1 Dismounting steps Warning Before dismounting be aware of dangerous process con ditions such as e g pressure in the vessel high temperatures corrosive or toxic products etc Take note of chapters Mounting and Connecting to power Supply and carry out the listed steps in reverse order With Ex instruments the housing cover may only be opened if there is no explosive atmosphere present 8 2 Disposal OPTISWITCH 3200 C consists of materials which can recycled by specialised recycling companies We have purposely designed the electronic modules to be easily separable WEEE directive 2002 96 EG This instrument is not subject to the WEEE directive 2002 96 EG and the respective national laws in Germany e g ElektroG Pass the instrument directly on to a specialised recycling company and do not use the municipal collecting points These may only be used for privately used products acc to the WEEE directive Correct disposal avoids negative effects to persons and environment and ensures recycling of use
20. e In hazardous areas you should take note of the appropriate regulations conformity and type approval certificates of the sensors and power supply units Connect the power supply acc to the following diagrams Take note of the general installation regulations As a rule connect OPTISWITCH 3200 C to vessel ground PA or in case of plastic vessels to the next ground potential On the side of the instrument housing there is a ground terminal between the cable entries This connection serves to drain off electrostatic charges In Ex applications the installation regulations for hazardous areas must be given priority The data for power supply are stated in the Technical data in the Supplement OPTISWITCH 3200 C is connected with standard cable with round cross section An outer cable diameter of 5 9 mm 0 2 0 35 in ensures the seal effect of the cable entry If cable with a different diameter or wire cross section is used exchange the seal or use an appropriate cable connection In hazardous areas only use approved cable connections for OPTISWITCH 3200 C Take note of the corresponding installation regulations for Ex applications 5 2 Connection procedure With Ex instruments the housing cover may only be opened if there is no explosive atmosphere present Proceed as follows 1 Unscrew the housing cover 2 Loosen compression nut of the cable entry OPTISWITCH 3200 C with two wire output col LO90 N3A 6S66 2
21. eight of the requested switching point Use the recommended cable see chapter Connecting to power supply and tighten the cable gland You can give your OPTISWITCH 3200 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 off This applies mainly to mounting outdoors in areas where moisture is expected e g by cleaning processes or on cooled or heated vessels Fig 2 Measures against moisture penetration Do not hold OPTISWITCH 3200 C on the vibrating element Especially with flange and tube versions the sensor can be damaged by the weight of the instrument Remove the protective cover just before mounting The process fitting must be sealed if there is gauge or low pressure in the vessel Before use check if the seal material is resistant against the measured product and the process temperature The vibrating level switch is a measuring instrument and must be treated accordingly Bending the vibrating element will destroy the instrument OPTISWITCH 3200 C with two wire output colt LO90 N3A 6S662 29959 EN 060112 Tensile load Material cone Mounting Warning The housing must not be used to screw the instrument in Applying tightening force on the housing can damage its internal mechanical parts To screw in use the hexagon above the thread 4 2 Mounting information Make sure t
22. epair gt Push the mode switch If the instrument then does not change the mode the oscillator may be defective Exchange the oscillator gt Check if there is buildup on the vibrating element and if so remove it Unfavourable installation location Mount the instrument at a location in the vessel where no dead zones or mounds can form gt Check if the vibrating element is covered by buildup on the socket Wrong mode selected gt Set the mode switch on OPTISWITCH 3200 C to max Set the correct mode on the signal conditioning instrument A overfill protection B dry run protection OPTISWITCH 3200 C with two wire output G 1 LO9O0 NA 6S66G 29959 EN 060112 d Signal lamp flashes red Electronics has detected a failure gt Exchange instrument or return it for repair 7 3 Exchanging the electronics In general all oscillators of series VB60 can be interchanged If you want to use an oscillator with a different signal output you can download the corresponding operating instructions man ual from our homepage under Downloads With EExd instruments the housing cover may only be opened Ex if there is no explosive atmosphere present Proceed as follows ch Switch off power supply Unscrew the housing cover Lift the opening levers of the terminals with a screwdriver Pull the connection cables out of the terminals on fF O ND Loosen the two screws with a Phillips screwdriver size 1
23. f FMEDA Failure Mode Effects and Diagnostics Analysis the following assumptions form the basis e Failure rates are constant wear of the mechanical parts is not taken into account e Failure rates of external power supplies are not included Multiple errors are not taken into account e The average ambient temperature during the operating time is 40 C 104 F e The environmental conditions correspond to an average industrial environment e The service lift of the components is between 8 to 12 years IEC 61508 2 7 4 7 4 remark 3 e The processing unit can interpret fail low and fail high failures as interferences and output a suitable fault signal OPTISWITCH 3200 C with two wire output 29 Functional safety Low demand mode High demand mode Safe condition and fault de scription 30 e The communication via the IIC bus interface is only used for default scaling and for service purposes e The repair time exchange of the measuring system after a fail safe error is eight hours MTTR 8 h e Inthe mode with the lowest demand rate the reaction time of a connected control and processing unit to dangerous detectable errors is max 1 hour If the demand rate is only once a year then the measuring system can be used as safety relevant subsystem in ow demand mode IEC 61508 4 3 5 12 If the ratio of the internal diagnostics test rate of the measuring system to the demand rate exceeds the value 100 the meas
24. ful raw materials Materials see Technical data If you cannot dispose of the instrument properly please contact us about disposal methods or return OPTISWITCH 3200 C with two wire output 27 Functional safety Validity Area of application Safety function Relevant standards Safety requirements 28 9 Functional safety 9 1 General This safety manual applies to measuring systems consisting of OPTISWITCH 3200 C vibrating level switches and integrated oscillator VB60Z The instrument corresponds to a subsystem of type B The sensor software must correspond at least to version 1 03 or higher The measuring system can be used for level detection of powders and granules which meet the specific requirements of the safety technology e g e Mode max for overfill protection e Mode min for dry run protection The measuring system is qualified in both modes to meet the following requirement degree acc to IEC 61508 2 e SIL2 with architecture 1001D single channel e SIL3 with architecture 1002D double channel redundant With a special factory setting the measuring system is also suitable for detection of solids in water see operating instructions manual The safety function of this measuring system is the detection and signalling of the condition of the vibration element The safe condition depends on the mode e In mode max condition covered e In mode min condition uncovered e IEC 61508
25. hat the max permissible tensile load of the suspension cable is not exceeded This danger exists particularly with very heavy solids and large meas lengths The max permissible load is stated in the Technical data in the Supplement In silos for bulk solids material cones can form and change the switching point Please keep this in mind when installing the sensor in the vessel We recommend selecting an installation location where the tuning fork detects an average value of the material cone The vibrating element must be mounted at a location that takes the arrangement of the filling and emptying apertures into account To compensate measurement errors caused by the material cone in cylindrical vessels the sensor must be mounted at a distance of d 6 from the vessel wall oja a E Fig 3 Filling and emptying centered OPTISWITCH 3200 C with two wire output 11 Mounting Socket Inflowing material 12 Fig 4 Filling in the center emptying laterally 1 OPTISWITCH 3200 C 2 Emptying opening 3 Filling opening The vibrating element should protrude into the vessel to avoid buildup For that reason avoid using mounting bosses for flanges and screwed fittings This applies particularly to use with adhesive products If OPTISWITCH 3200 C is mounted in the filling stream unwanted switching signals can be generated
26. installation 32 9 3 Setup The prevailing plant conditions influence the safety of the measuring system For this reason carefully observe the mounting and installation instructions in the operator s manual It is especially important to make sure the mode setting min max is correct 9 4 Reaction during operation and in case of failure e The adjustment elements must not be modified during operation e f modifications have to be made during operation carefully observe the safety functions e Fault signals that may appear are described in the appropriate operating instructions manual e Incase of detected failures or fault signals the entire measuring system must be switched out of service and the process held in a safe condition by means of other measures e An electronics exchange is easily possible and described in the operating instructions manual e f due to the detected failure the electronics or the complete sensor is exchanged the manufacturer must be informed incl a fault description 9 5 Recurring function test The recurring function test serves to reveal potential danger ous errors that are otherwise not discernible The function of the measuring system must be checked at adequate intervals The operator is responsible for choosing the type of test and the intervals in the stated time frame The time frame depends on the PFDayg value acc to the chart and diagram in section Safety related characteri
27. n This operating instructions manual has all the information you need for quick setup and safe operation Please read this manual before you start setup 1 2 Target group This operating instructions manual is directed to trained personnel The contents of this manual should be made available to these personnel and put into practice by them 1 3 Symbolism used Information tip note This symbol indicates helpful additional information Caution warning danger This symbol informs you of a dangerous situation that could occur Ignoring this cautionary note can impair the person and or the instrument Ex applications This symbol indicates special instructions for Ex applications List The dot set in front indicates a list with no implied sequence Action This arrow indicates a single action Sequence Numbers set in front indicate successive steps in a procedure OPTISWITCH 3200 C with two wire output col LO90 N3A 6S66 2 29959 EN 060112 For your safety 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 operator For safety and warranty reasons any internal work on the instruments must be carried out only by personnel authorised by the manufacturer 2 2 Appropriate use OPTISWITCH 3200 C is a sensor for level detection Detailed information on the application range of OPTISW
28. n using a signal conditioning instrument always set the mode switch to max mode In this case you select the requested mode acc to the Function chart max max detection or overfill protection OPTISWITCH 3200 C with two wire output 21 Setup min min detection or dry run detection on the signal conditioning instrument When used on a control system the following values apply e min mode Vibrating element uncovered 16 mA 1 mA Vibrating element covered 8 mA 1 mA e max mode vibrating element uncovered 8 mA 1 mA vibrating element submerged 16 mA 1 mA Signal lamp 5 Control lamp for indication of the switching condition e green 8mA e red 16 mA e red flashing Failure 2 3 mA 6 3 Function chart OPTISWITCH 3200 C level sensor The following chart provides an overview of the switching conditions depending on the adjusted mode and level Mode on the sensor Level Signal current Sensor Signal lamp sensor max 8 mA Overfill protection Green MEDE approx 16 mA Overfill protection min approx 8 mA Dry run protection min approx 16 mA Dry run protection ER LI red 22 OPTISWITCH 3200 C with two wire output col LO90 NA 6S66 2 29959 EN 060112 Setup Fault signal min max mode flashes red OPTISWITCH 3200 C level switch with signal conditioning instrument The following chart provides an overview of the s
29. nd terminal Terminals Control lamp AR Co bh A For connection to a signal conditioning instrument The sensor is powered via the connected signal conditioning instrument For further information see the Technical data in the Supple ment The wiring example is applicable for all suitable signal conditioning instruments If the mode switch of OPTISWITCH 3200 C is correctly set to max then the signal lamp on OPTISWITCH 3200 C lights OPTISWITCH 3200 C with two wire output ol LO90 NA 6S66 2 29959 EN 060112 Connecting to power supply e red with submerged vibrating element e green with uncovered vibrating element Take note of the operating instructions manual of the signal conditioning instrument Suitable signal conditioning instru ments are listed under Technical data Fig 11 Wiring plan 1 Voltage supply OPTISWITCH 3200 C with two wire output 19 Setup Function Configuration 20 Pale 6 Setup 6 1 General The numbers in brackets refer to the following illustrations On the electronics module you will find the following indicating and adjustment elements e Potentiometer for switching point adaptation 1 e DIL switch for mode adjustment min max 2 e Signal lamp 5 Note As a rule always set the mode with mode switch 2 before starting the setup of OPTISWITCH 3200 C If the instrument is used in conjunction with
30. ousing 2 Stainless steel housing 3 Aluminium housing 7 All dimensions in mm inch 29959 EN 060112 OPTISWITCH 3200 C with two wire output 41 Supplement 0 OUO 9 L kl Di CAH gl 33mm 1 19 64 SC Se aes Tel ISS G1VA lew 43mm 1 11 46 22mm 55 64 11mm 7 16 43mm 1 11 46 L 160mm 6 19 64 150mm 5 29 39 A A Fig 16 OPTISWITCH 3200 C Threaded version G1 2A L Sensor length see Technical data 42 OPTISWITCH 3200 C with two wire output GL LO90 N3A 6S66 2 29959 EN 0601 12 KROHNE Supplement 10 3 Certificates SIL declaration of conformity declaration of conformity Konformitatserklarung Declaration de conformite IEC 61508 IEC 61511 KROHNE 5 4 5 Les Ors 26103 ROMANS France erkl rt als Hersteller dass die Vibrationsgrenzschalter declares as manufacturer that the vibrating level switches d clare en tant que fabricant que les d tecteurs vibrants OPTISWITCH 3100 C 3200 C 3300 C mit with avec VB60C R T N Z Ex entsprechend der IEC 61508 f r den Einsatz in sicherheitsinstrumentierten Systemen geeignet sind Die Sicherheitstechnische Kennzahlen sowie die Sicherheitshinweise im Safety Manual sind zu beachten siehe entsprechende Betriebsanleitung Kapitel Funktionale Sicherheit according to IEC 61508 are suitable for safety instrumented systems SIS The safety
31. r 1 year lt 0 018 x 10 Tproot 5 years lt 0 091 x 10 Tproor 10 years lt 0 184 x 10 PFH 1 h lt 2 3 x 10 h Mode switch is set to min OPTISWITCH 3200 C with two wire output col LO90 NA 6S66 2 29959 EN 060112 Time dependent process of PFDavg Functional safety PFDavg Tproot 1 year lt 0 016 x 10 Tproof 5 years lt 0 079 x 10 Tproot 10 years lt 0 160 x 10 PFH 1 h lt 2 1x10 h The time dependent process of PFDayg reacts in the time period up to 10 years virtually linear to the operating time The above values only apply to the Tproco interval after which a recurring function test must be carried out Fig 14 Time dependent process of PFDayg 1 PFDavg O 2 PFDavg after 1 year 3 PFDa after 5 years 4 PFDa after 10 years 2 Numbers see in the above charts OPTISWITCH 3200 C with two wire output 37 Supplement 10 Supplement 10 1 Technical data General data Material 316L corresponds to 1 4404 or 1 4435 Materials wetted parts Process fitting Thread Process fitting Flange Process seal Seal vibrating element Tuning fork Suspension cable Materials non wetted parts Housing Seal ring between housing and housing cover Ground terminal Weights with plastic housing with Aluminium housing with stainless steel housing Suspension cable Max permissi
32. re 10 h 39 FIT safe detected failure 373 FIT safe undetected failure 168 FIT dangerous detected failure 36 FIT dangerous undetected failure Diagnosis coverage DCs Agq Aga Asu Diagnosis coverage DCD Add Aga Adu 352 FIT safe undetected failure dangerous detected failure dangerous undetected failure Safe Failure Fraction Diagnosis coverage DCs Agq Aga Asu Diagnosis coverage DCp Agd Aga Adu 39 FIT safe detected failure OPTISWITCH 3200 C with two wire output colt LO90 NA 6S66 2 29959 EN 060112 General data Architecture 1001D Overfill protection Architecture 1001D Dry run protection Functional safety Diagnosis coverage DCs Agq Asa Asu Diagnosis coverage DCD Aga Aad Adu TDiagnosis Diagnosis test period 100 sec MTBF MTTF MTTR 1 59x10 h max useful life of the measuring system for the safety approx 10 years function Single channel architecture SIL2 Safety Integrity Level HFT 0 Hardware Fault Tolerance Mode switch is set to max PFDavg Tproor 1 year lt 0 008 x 10 Tproof 5 years lt 0 039 x 107 Tproof 10 years lt 0 077 x 107 PFH 1 h lt 1 8 x 108 h Mode switch is set to min PFDavg Tproor 1 year lt 0 016 x 107 Tproof 5 years lt 0 078 x 107 Tproor 10 years lt 0 156 x 107 PFH 1 h lt 3 6 x 10 h SIL2 Safety Integrity Level HFT 0 Hardware Fault Tolerance Mode switch
33. stics In high demand rate no recurring function test is arranged in IEC 61508 A proof of the functional efficiency is seen in the more frequent demand of the measuring system In double channel architectures it is useful to proof the redundancy by recurring function tests in appropriate intervals The test must be carried out in a way that verifies the flawless operation of the safety functions in conjunction with all system components OPTISWITCH 3200 C with two wire output colt LO90 NA 6S66 2 29959 EN 0601 12 Recurring function test when using the measuring system as overfill protection Functional safety This is ensured by a controlled reaching of the response height during filling If filling up to the response height is not possible then a response of the measuring system must be triggered by a suitable simulation of the level or the physical effect The methods and procedures used during the tests must be stated and their suitability must be specified The tests must be documented If the function test proves negative the entire measuring system must be switched out of service and the process held in a safe condition by means of other measures In the double channel architecture 1002D this applies separately to both channels If the measuring system is used as overfill protection the proof of the function is ensured by a simple function test which can be triggered and monitored manually or by a connected con
34. the mode switch on the sensor to max Use as overfill protec Use as dry run pro tion system tection system Safe condition covered uncovered Output current in safe 12 5 mA 23 5 mA 2 3 mA 11 5 mA condition Error current Fail Low Error current Fail High gt 23 5 mA gt 23 5 mA Set the mode switch on the sensor to min Use as overfill protec Use as dry run pro tion system tection system Safe condition covered uncovered Output current in safe 2 3 mA 11 5 MA 12 5 mA 23 5 mA condition Error current Fail Low Error current Fail High gt 23 5 mA gt 23 5 MA If the measuring system delivers output currents of lt 2 3 mA Fail Low or gt 23 5 mA Fail High this may indicate a failure The processing unit must therefore interpret such currents as failure and output a suitable fault signal If this is not the case the appropriate shares of the failure rates must be assigned to the dangerous failures Therefore the stated values in chapter Safety relevant characteristics can deteriorate The processing unit must correspond to the SIL level of the measuring chain If a SU 501 Ex is used for evaluation the mode switch on the sensor must be set to max The signal conditioning instru ment SU 501 Ex must be operated acc to the quiescent current principle use closing contact of the relay OPTISWITCH 3200 C with two wire output 31 Functional safety Mounting and
35. trol system This function test is triggered by interrupting the supply cable for at least two seconds then a switch on procedure follows as described in the operating instructions manual If the test is carried out this way make sure that the vibrating element is not covered If the evaluation is made by a control system the correct sequence of the current change must be checked and documented If a connected signal conditioning instrument is used for evaluation the recurring function test can be carried out by simply pressing the test key on the signal conditioning instrument You will find more details in the operating instructions manual of the signal conditioning instrument Suitable signal conditioning instruments are listed under Technical data 9 6 Safety related characteristics The failure rates of the electronics and the vibrating system were determined by an FMEDA acc to IEC 61508 Basis for the calculations are component failure rates acc to SN 29500 All values relate to an average ambient temperature of 40 C 104 F during operation The calculations are further based on the instructions stated in chapter Planning OPTISWITCH 3200 C with two wire output 33 Functional safety Overfill protection Dry run protection 34 Mode switch is set to max 387 FIT safe undetected failure 163 FIT dangerous detected failure 18 FIT dangerous undetected failure 49 FIT safe detected failure 1 FIT failu
36. uring system can be treated in the way it is executing a safety function in the mode with low demand rate IEC 61508 2 7 4 3 2 5 Corresponding characteristics is the value PFDavg average Probability of dangerous Failure on Demand It is dependent on the test interval Ter between the function tests of the protective function For number values see paragraph Safety technical charac teristics If the low demand rate does not apply the measuring system as safety relevant part system in high demand mode should be used IEC 61508 4 3 5 12 The fault tolerance time of the complete system must be higher than the sum of the reaction times or the diagnostics test periods of all components in the safety chain Corresponding characteristics is the value PFH failure rate For number values see paragraph Safety technical charac teristics A safe failure exists if the measuring system goes to the defined safe condition without being required by the process or the interference current outputs Fail low or Fail high If the internal diagnostics system detects an error a fault current of lt 2 3 mA will be outputted A dangerous undetected failure exists if the measuring system switches neither to the defined safe condition nor to failure mode when the process requires it OPTISWITCH 3200 C with two wire output col LO90 NA 6S662 29959 EN 060112 Configuration of the process ing unit Functional safety Set
37. witching conditions depending on the adjusted mode of the signal conditioning instrument and the level Note Keep in mind that the mode switch of OPTISWITCH 3200 C must be always set to max Mode on the signal Signal current Signal lamp sensor Signal lamp sig conditioning instru Sensor nal conditioning ment instrument Mode A approx 8 mA Overfill protection P Mode A approx 16 mA Overfill protection i Mode B approx 16 mA Dry run protection Mode B approx 8 mA Dry run protection any Fault signal mode A B 1 You will find suitable signal conditioning instruments in the Technical data OPTISWITCH 3200 C with two wire output 23 Maintenance and fault rectification Checking the switching signal 24 7 Maintenance and fault rectification 7 1 Maintenance When used as directed in normal operation OPTISWITCH 3200 C is completely maintenance free 7 2 Fault rectification d OPTISWITCH 3200 C signals covered when the vibrating element is not submerged overfill protection d OPTISWITCH 3200 C signals uncovered when the vibrating element is submerged dry run protection Supply voltage too low gt Check the power supply Electronics defective gt Push the mode switch min max If the instrument then changes the mode the instrument may be mechanically damaged Should the switching function in the correct mode still be faulty return the instrument for r
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