Operating Instructions - OPTISWITCH 3200 C with relay
Contents
1. YONG GE DAA Oh Fig 12 Electronics module VB 60R Relay output Potentiometer for switching point adaptation DIL switch for mode adjustment Ground terminal Terminals Control lamp D ES LG M A OPTISWITCH 3200 C with relay output cL LOUNT Zoppe 29957 EN 060112 Switching point adaptation 1 Mode adjustment 2 Signal lamp 5 Setup 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 change the switching condition of the relay You can set the required mode acc to the Function chart max max detection or overfill protection min min detection or dry run protection We recommend connecting acc to the quiescent current principle re2. To screw in use the hexagon above the thread 4 2 Mounting information Make sure that 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 S Fig 3 Filling and emptying centered OPTISWITCH 3200 C with relay 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 OPTISWITC
3. 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 ristiques 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 curit fonctionnelle Romans 21 10 2005 KROHNE S A S L KN Dr Florian Stengele Gesch ftsf hrer Managing Director Directeur g n ral Fig 17 SIL declaration of conformity 40 OPTISWITCH 3200 C with relay output cL LO9O0 NA LS66G 29957 EN 060112 CE declaration of conformity CE Konformit tserkl rung Declaration of conformity D claration de conformit Krohne S A S Les Ors BP uN F 26103 Romans Cedex erkl rt in alleiniger Verantwortung da 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 VB60Z auf das sich diese Erklarung bezieht mit den folgenden Normen bereinstimmt to which this declaration relates is in conformity with the following standards auquel se
4. 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 OPTISWITCH 3200 C with relay output cL LO90 NA ZS66 2 29957 EN 060112 Overfill protection Functional safety 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 characteristics 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 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 m
5. with relay output cL LO90 NA ZS66 e 29957 EN 060112 Packaging Storage and transport tem perature Product description 3 3 Adjustment With the factory setting products with a density of gt 0 02 g cm gt 0 0008 Ibs in can be measured It is possible to adapt the instrument for products with lower density gt 0 008 g cm gt 0 0003 Ibs in On the electronics module you will find the following indicating and adjustment elements 6 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 relay 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 an
6. C with relay output 29 Functional safety Configuration of the process ing unit Mounting and installation 30 A dangerous undetected failure exists if the measuring system does not go to the defined safe condition when required by the process The processing unit must evaluate the output circuit of the measuring system by taking the quiescent current principle into account The processing unit must correspond to the SIL level of the measuring chain 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
7. Stainless steel housing Aluminium housing 38 3 All dimensions in mm inch OPTISWITCH 3200 C with relay output cL LO90 NA ZS66 e 29957 EN 060112 22mm 160mm 6 19 64 150mm 5 29 39 Fig 16 OPTISWITCH 3200 C Threaded version G1 2A L Sensor length see Technical data OPTISWITCH 3200 C with relay output Supplement 0 OUO S ell Se TT se emm a ge KH s e 3 GTA Eeu CA R 11mm ie ESCH E 8 0 43mm 111 46 RY n Dr 39 Supplement 10 3 Certificates SIL declaration of conformity declaration of conformity Konformitatserklarung D claration de conformit IEC 61508 IEC 61511 KROHNE S A S 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 VB6OC 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 related characteristics as well as the instructions of the safety manual must be considered
8. 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 Download 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 relay output 25 Dismounting 26 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 u
9. r f re cette d claration est conforme aux normes Emission Emission Emission EN 61326 1997 Klasse B Immission Susceptibility Immission EN 61326 1997 A1 1998 EN 61010 1 2001 gem den Bestimmungen der Richtlinien following the provision of Directives conform ment aux dispositions des Directives 73 23 EWG 89 336 EWG Q ei o O Y 07 07 2004 L eu LN p p P O Florian Stengele Supplement Fig 18 CE declaration of conformity OPTISWITCH 3200 C with relay output 41 Supplement 42 OPTISWITCH 3200 C with relay output ol LOUNT Zoppe 29957 EN 060112 OPTISWITCH 3200 C with relay output Supplement 43 Subject to change without notice 29957 EN 060112
10. the housing cover may only be opened if there is no explosive atmosphere present Proceed as follows OPTISWITCH 3200 C with relay output cL LO9O0 NA LS66G 29957 EN 060112 Connecting to power supply Unscrew the housing cover Loosen compression nut of the cable entry 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 Insert the cable into the sensor through the cable entry Lift the opening levers of the terminals with a screwdriver see following illustration Insert the wire ends into the open terminals according to the wiring plan Press down the opening levers of the terminals you will hear the terminal spring closing Check the hold of the wires in the terminals by lightly pulling on them 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 OPTISWITCH 3200 C with relay output 17 Connecting to power supply 2 Housing overview Electronics and connection compartment Wiring plan 18 5 3 Wiring plans single chamber housing The following illustrations apply to the non Ex as well as to the EEx d version Fig 9 Material versions single chamber housing Plastic not with EEx d Aluminium Stainless steel not with EEx d Filter element for
11. 20 80 C 4 176 F gt 0 02 g cm gt 0 0007 Ibs in gt 0 008 g cm gt 0 0003 Ibs in e 1x cable entry M20x1 5 cable 95 9 mm 1x blind stopper M20x1 5 attached 1x cable entry M20x1 5 or e 1x cable entry 12 NPT 1x blind stopper Ya NPT 1x cable entry 12 NPT or e 1x plug M12x1 1x blind stopper M20x1 5 for wire cross section up to 1 5 mm 0 0023 in OPTISWITCH 3200 C with relay output cL LO9O0 NA LS66G 29957 EN 060112 Adjustment elements Mode switch min max Voltage supply Power supply Power consumption Electrical protective measures Protection Overvoltage category Protection class Approvals ATEX II 1 2G 2G EEx d IIC T6 ATEX II 1 2 D IP66 T 2 Supplement min detection or dry run protection max detection or overfill protection 20 253 V AC 50 60 Hz 20 72 V DC with U gt 60 V DC the ambiet temperature can be max 50 C 122 F 1 8 VA AC approx 1 3 W DC IP 66 IP 67 III Deviating data with Ex applications see separate safety instructions OPTISWITCH 3200 C with relay output 37 Supplement 10 2 Dimensions OPTISWITCH 3200 C 2 23 39 377mm 3 1 39 4 13 32 69mm 2 23 39 M20x1 5 Ye NPT 77mm 3 1 39 4 39 64 116mm 4 9 416 84mm 3 5 16 4 31 64 Fig 15 Housing versions 1 2 3 Plastic housing
12. H 3200 C is mounted in the filling stream unwanted switching signals can be generated 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 relay output ol LOUNT Zoppe 29957 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 relay 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 relay output ol LOUNT Zoppe 29957 EN 060112 Mounting Fig 7 Baffle protection against damages OPTISWITCH 3200 C with relay output 15 Connecting to power supply Note safety instructions Take note of safety instructions for Ex Ex applications Select power supply Select connection cable Select connection cable for Ex applica tions EI 2 16 5 Connecting to power supply 5 1 Preparing the connection Always observe the following safety in
13. HFT 1 Hardware Fault Tolerance Mode switch is set to min PFDavg Tproot 1 year lt 0 016 x 10 Tproof 5 years lt 0 081 x 10 Tproof 10 years lt 0 160 x 10 PFH 1 h lt 1 7x10 h OPTISWITCH 3200 C with relay output 33 Functional safety Time dependent process of PFDavg 34 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 Tproor interval after which a recurring function test must be carried out 1 5 10 Tproot Fig 14 Time dependent process of PFDavg 1 PED 0 2 PFDavg after 1 year 3 PED after 5 years 4 1 PFDa after 10 years Numbers see in the above charts OPTISWITCH 3200 C with relay output ol LOUNT Zoppe 29957 EN 060112 10 Supplement 10 1 Technical data General data Supplement 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 permissible tensile load Sensor length Output variable Output Turn on voltage
14. Operating Instructions OPTISWITCH 3200 C with relay 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 ti lt Tie rte N EER he AE we d 1 2 Target GOUD ss eis r NE Re s Re ED gode d 13 Symbolism used SESSE SE 4 2 For your safety 2 1 Authorised personnel a a aaa aoaaa anaa 5 2 2 Appropriate use naaa aaa a 5 2 3 Warning about misuse a na naana aa 5 2 4 General safety instructions 5 2 5 CE conformity the coed adie dae e wad 5 2 6 SIL conformity n SEE EE SE SE ae 6 2 7 Safety information for Ex areas 6 3 Product description 3 1 Configuration aa aaa aaae SE ee eee 7 3 2 Principle of operation aaaea aaaea D 3 3 Adjustment SS SE Se se 9 34 Storage and transport 9 4 Mounting 4 1 General instructions n aaeanoa 10 4 2 Mounting information EES SE 11 5 Connecting to power supply 5 1 Preparing the connection 16 5 2 Connection procedure 05 16 5 3 Wiring plans single chamber housing 18 6 Setup 6 1 General 20 6 2 Adjustment elements oana naaa aaa 20 6 3 Function chat 21 7 Maintenance an
15. art of the operating instructions manual and come with the Ex approved instruments OPTISWITCH 3200 C with relay output ol LOUNT Zoppe 29957 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 relay 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 exter
16. be used as safety relevant subsystem in low 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 measuring 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 PFDa average Probability of dangerous Failure on Demand It is dependent on the test interval T paar 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 The safe condition of the measuring system is the switched off status quiescent current principle e VB6OR relay output Relay deenergized A fail safe failure safe failure exists if the measuring system changes to the defined safe condition without demand of the process If the internal diagnosis system recognises a failure the safe condition is taken up OPTISWITCH 3200
17. d fault rectification 7 1 Maintenance 23 7 2 FaultrectficatiOh ESE SE see 23 7 3 Exchanging the electronics 24 7 4 Instrument repair 2 0 2 0 0 2 ee eee 25 8 Dismounting 8 1 Dismounting steps 26 8 2 Disposal 0 cc ee ee 26 OPTISWITCH 3200 C with relay output ol LO90 NA ZS66 e 29957 EN 060112 Contents 9 Functional safety 91 EE ER FEE ET 27 92 Planning 28 93 SCD as koa owas HR Eee eo oS ae S 30 9 4 Reaction during operation and in case of failure 30 9 5 Recurring function test 04 30 9 6 Safety related characteristics 31 10 Supplement 10 1 Technical data 35 10 2 Dimensions 0 0 00 0 eee eee 38 10 3 Certificates oana ee 40 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 6 Operating instructions manual Cable shortening set OPTISWITCH 3200 C with relay output 3 About this docume
18. easuring 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 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 Mode switch is set to max 0 FIT safe detected failure 1 FIT failure 10 h 586 FIT safe undetected failure 124 FIT dangerous detected failure Safe Failure Fraction 27 FIT dangerous undetected failure OPTISWITCH 3200 C with relay output 31 Functional safety Dry run protection General data Architecture 1001D Overfill protection 32 Diagnosis coverage DCs Agq Asa Asu Diagnosis coverage DCD Aga Aad Adu Mode switch is set to min safe detected failure safe undetected failure dangerous detected failure dangerous undetected failure Safe Failure Fraction Diagnosis coverage DCs Asa Asd Asu 78 Diagnosis coverage DCD Add Aga Adu TDiagnosis Diagnosis test period 100 sec MTBF MTTF MTTR 1 33x10 h max useful life of the measuring system for the safety approx 10 years fu
19. ed information on the application range of OPTISWITCH 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 relay 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 p
20. f power supply Unscrew the housing cover Lift the opening levers of the terminals with a screwdriver Pull the connection cables out of the terminals ao A O N Loosen the two screws with a Phillips screwdriver size 1 Fig 13 Loosen the screws 1 Electronics module 2 Screws 2 pcs 6 Remove the old oscillator OPTISWITCH 3200 C with relay output ol LOUNT Zoppe 29957 EN 060112 Maintenance and fault rectification 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
21. min max Switching current min max OPTISWITCH 3200 C with relay output 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 lbs 0 3 80 m 1 262 ft relay output DPDT 2 floating spdts 10 mV 253 V AC 253 V DC 10 HA 3AAG 1ADG 35 Supplement Breaking capacity min max Contact material relay contacts 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 dependent on the version Single chamber housing Spring loaded terminals 36 50 mW 750 VA AC 54 W DC If inductive loads or stronger currents are switched through the gold plating on the relay contact surface will be permanently damaged The contact is then no longer suitable for switching low level signal circuits AgNi or AgSnO and Au plated min max approx 0 5 s approx 1s 40 80 C 40 176 F 40 80 C 40 176 F level of solids 1 6 bar 100 600 kPa 14 5 87 psi
22. nal vibration or changing products Solid detection in water If OPTISWITCH 3200 C was ordered for solid 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 if 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 or in case the power supply fails the electronics takes on a defined switching condition i e the relay deenergizes safe condition 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 OPTISWITCH 3200 C is a compact instrument i e it can be operated without external evaluation system The integrated electronics evaluates the level signal and outputs a switching signal With this switching signal a connected device can be operated directly e g a warning system a PLC a pump etc The exact range of the voltage supply is specified in the Technical data in the Supplement OPTISWITCH 3200 C
23. nction Single channel architecture SIL2 Safety Integrity Level HFT 0 Hardware Fault Tolerance Mode switch is set to max PED Tproor 1 year lt 0 012 x 107 Tproot 5 years lt 0 059 x 107 Taar 10 years lt 0 118 x 107 PFH 1 h lt 2 7 x 10 h OPTISWITCH 3200 C with relay output cL LOUNT Zoppe 29957 EN 060112 Architecture 1001D Dry run protection Architecture 1002D Overfill protection Architecture 1002D Dry run protection Functional safety SIL2 Safety Integrity Level HFT 0 Hardware Fault Tolerance Mode switch is set to min PFDavg T proof 1 year lt 0 016 x 10 Tproof 5 years lt 0 082 x 107 Trroof 10 years lt 0 164 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 HET 1 Hardware Fault Tolerance Mode switch is set to max PFDavg Trroof 1 year lt 0 012 x 10 Tproof 5 years lt 0 059 x 10 Tproot 10 years lt 0 120 x 10 PFH 1 h lt 1 5x10 h SIL3 Safety Integrity Level
24. nt EI Pme d 1 About this document 1 1 Function This operating instructions manual has all the information you need for duick 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 relay output ol LOUNT Zoppe 29957 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 Detail
25. ollowing items for use as dry run protection system Avoid buildup on the vibrating system possibly smaller proof test intervals Avoid granulation size of the product gt 15 mm For the implementation of FMEDA Failure Mode Effects and Diagnostics Analysis the following assumptions form the basis Failure rates are constant wear of the mechanical parts is not taken into account Failure rates of external power supplies are not included Multiple errors are not taken into account The average ambient temperature during the operating time is 40 C 104 F The environmental conditions correspond to an average industrial environment The lifetime of the components is around 8 to 12 years IEC 61508 2 7 4 7 4 remark 3 The processing unit evaluates the output circuit of the measuring system acc to the quiescent current principle OPTISWITCH 3200 C with relay output cL LOUNT Zoppe 29957 EN 060112 Low demand mode High demand mode Safe condition and fault de scription Functional safety 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
26. play contact deenergizes when reaching the switching point because the relay takes on the same safe condition if a failure is detected Control lamp for indication of the switching condition e green relay energized e red relay deenergized e red flashing failure 6 3 Function chart The following chart provides an overview of the switching conditions depending on the adjusted mode and level max mode Overfill protection 6 7 Relay energized max mode Overfill protection 7 3 4 5 6 7 8 Relay deener gized OPTISWITCH 3200 C with relay output 21 Setup 22 min mode Dry run protection min mode Dry run protection Failure of the Supply voltage min max mode Failure Wei 3 4 5 6 7 8 Relay energized 3 4 5 6 7 8 Relay deener Relay deener flashes red gized OPTISWITCH 3200 C with relay output cL LOUNT Zoppe 29957 EN 060112 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 Checking the switching signal 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 defec
27. 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 Ground terminal Terminals Control lamp D P G M A We recommend connecting OPTISWITCH 3200 C in such a way that the switching circuit is open when there is a level signal line break or failure Safe condition ol LOUNT Zoppe OPTISWITCH 3200 C with relay output 29957 EN 060112 Connecting to power supply The relays are always shown in non operative condition De SE DI DI D 345678 min LO max N N Fig 11 Wiring plan 1 Relay output 2 Relay output 3 Voltage supply OPTISWITCH 3200 C with relay 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 6 Signal lamp 5 Note As a rule always set the mode with mode switch 2 before starting the setup of OPTISWITCH 3200 C The switching output will change if you set the mode switch 2 afterwards This could possibly trigger other connected instruments or devices 6 2 Adjustment elements
28. se 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 useful 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 relay output ol LOUNT Zoppe 29957 EN 060112 Validity Area of application Safety function Relevant standards Safety requirements Functional safety 9 Functional safety 9 1 General This safety manual applies to measuring systems consisting of OPTISWITCH 3200 C vibrating level switches and integrated oscillator VB6OR 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 func
29. structions 6 Connect only in the complete absence of line voltage 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 Oscillator VB 6OR is designed in protection class 1 To maintain this protection class it is absolutely necessary that the ground conductor be connected to the internal ground terminal Take note of the general installation regulations 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 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 wire 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
30. tion of this measuring system is the detection and signalling of the condition of the vibration element The safe condition depends on the mode 6 In mode max condition covered 6 In mode min condition Uncovered e IEC 61508 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 PFDavg gt 10 up to lt 10 gt 10 up to 108 gt 10 up to lt 10 gt 10 up to lt 107 gt 10 up to lt 10 gt 10 up to lt 10 gt 10 up to 107 gt 10 up to lt 10 OPTISWITCH 3200 C with relay output 27 Functional safety General instructions and re strictions Assumptions 28 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 SIL1 SIL2 90 up to lt 99 SIL2 SIL3 9 2 Planning The measuring system must be used acc to the application The application specific limits must be maintained and the specifications not exceeded Acc to the specifications in the operating instructions manual the current load of the output circuits must be within the limits It must be used only in products to which the materials of the vibrating system are sufficiently chemically resistant Note the f
31. tive 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 repair 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 correct mode on the mode switch max overfill protection min dry run protection Wiring should be carried out acc to the quiescent current principle OPTISWITCH 3200 C with relay output 23 Maintenance and fault rectification 24 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 if there is no explosive atmosphere present Proceed as follows ch Switch of
32. y position The instrument must be mounted in such a way that the vibrating element is at the height 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 relay output cL LO9O0 NA LS66G 29957 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
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