Operating Instructions - OPTISWITCH 3200 C with
Contents
1. Failure 22 Switch open flashes red OPTISWITCH 3200 C with contactless electronic switch cL L090 N3 9S666 29956 EN 0601 12 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 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 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 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 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 acc2. is a sensor for level detection Detailed 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 A1 1998 class B Susceptibility EN 61326 1997 A1 1998 e LVD EN 61010 1 2001 The instrument is designed for industrial use OPTISWITCH 3200 C with contactless electronic switch 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 Safety information for Ex areas Please note
3. processing unit evaluates the output circuit of the measuring system acc to the quiescent current principle OPTISWITCH 3200 C with contactless electronic switch ol L090 N3 9S666 29956 EN 0601 12 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 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 Tproor 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 deman
4. 2 Architecture 1002D Overfill protection Architecture 1002D Dry run protection Time dependent process of PFDavg Functional safety 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 96 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 Tproof si year lt 0 018 x 10 Tproof 5 years lt 0 090 x 10 Tproor 10 years lt 0 180 x 10 PFH 1 h lt 1 7 x 10 9 h SIL3 Safety Integrity Level HFT z 1 Hardware Fault Tolerance Mode switch is set to min PFDavg Tproof 1 year lt 0 025 x 10 Tproor 5 years lt 0 120 x 10 Tproor 10 years lt 0 250 x 10 PFH 1 h lt 1 9x10 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 Tproor interval after which a recurring function test must be carried out OPTISWITCH 3200 C with contactless electronic switch 33 Functional safety 34 10 TProof Fig 14 Time dependent process of PFDavg KON 1 P
5. 6 FIT safe undetected failure 124 FIT dangerous detected failure Safe Failure Fraction 41 FIT dangerous undetected failure OPTISWITCH 3200 C with contactless electronic switch 31 Functional safety Dry run protection General data Architecture 1001D Overfill protection Architecture 1001D Dry run protection 32 Diagnosis coverage DCs Agq Asa As Diagnosis coverage DCD Aga Aad Adu Mode switch is set to min O FIT safe detected failure safe undetected failure dangerous detected failure dangerous undetected failure Safe Failure Fraction Diagnosis coverage DCs Asa Asd Asu Diagnosis coverage DCD Add Aga Adu Tpiagnosis Diagnosis test period 100 sec MTBF MTTF MTTR 1 45X10 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 Tproot 1 year lt 0 018 x 107 Tproot 5 years lt 0 089 x 107 Tproor 10 years lt 0 178 x 107 PFH 1 h lt 4 1 x 10 h SIL2 Safety Integrity Level HFT z 0 Hardware Fault Tolerance Mode switch is set to min PFDavg Tproor 1 year lt 0 024 x 107 Tproot 5 years lt 0 122 x 107 Tproor 10 years lt 0 243 x 107 PFH 1 h lt 5 6 x 109 h OPTISWITCH 3200 C with contactless electronic switch cL L090 N3 9S666 29956 EN 0601 1
6. C with contactless electronic switch 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 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 contactless electronic swit
7. FDavg 0 PFDa after 1 year PFDa after 5 years PFDay g after 10 years Numbers see in the above charts OPTISWITCH 3200 C with contactless electronic switch col L090 N3 9S666 29956 EN 0601 12 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 Modes adjustable Integration time when immersed when laid bare Ambient conditions Ambient temperature on the housing Storage and transport temperature 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 Contactless electronic switch min max approx 0 5 s approx 1 s 40 80 C 40 40 80 C 40 176 F 176 F OPTISWITCH 3200 C with con
8. Operating Instructions OPTISWITCH 3200 C with contactless electronic switch 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 uie oe OE ee dn ee wie eee 5 12 Target group 0 2 eee o 13 Symbolism use o 2 For your safety 2 1 Authorised personnel LL 6 2 2 Appropriate use llle 6 2 3 Warning about misuse ss 6 2 4 General safety instructions 6 2 5 CE conformity 0 0 00 aee 6 2 6 SIL conformity 0 2 00 eee 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 naaa auaa 10 3 4 Storage and transport 10 4 Mounting 4 1 General instructions SESSE SES aa 11 4 2 Mounting information aaa aaa aaa aa 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 19 6 Setup 6 1 General 21 6 2 Adjustment elements EN 6 3 Function chat 22 7 Maintenance and fault rectification 7 1 Ma
9. ate safety instructions OPTISWITCH 3200 C with contactless electronic switch 37 Supplement 10 2 Dimensions OPTISWITCH 3200 C 2 23 39 oa 77mm 3 1 39 4 13 35 69mm 2 23 39 M20x1 5 Ye NPT L 116mm E 4 9 16 o 7 mm 8 130 84mm 3 5 16 4 39 64 4 31 64 Fig 15 Housing versions 1 2 3 Plastic housing Stainless steel housing Aluminium housing 38 3 All dimensions in mm inch OPTISWITCH 3200 C with contactless electronic switch col L090 N3 9S666 29956 EN 0601 12 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 contactless electronic switch Supplement 0 OUO S ell Se TT 8 emm Se e ge KH s e 3 GTA Eeu CL IJ d 11mm 7 16 ESCH EN d pn n Hi 39 Supplement 10 3 Certificates SIL declaration of conformity Konformitatserklarung declaration of conformity 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 VB60C R T N Z Ex entsp
10. ch cL L090 N3 9S666 29956 EN 0601 12 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 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 3 n Fig 3 Filling and emptying centered OPTISWITCH 3200 C with contactless electronic switch 11 Mounting Socket Inflowing material 12 Fig 4 Filling in the center emptying laterally 1 OPTISWITCH 3200 C 2 Empt
11. cial 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 20 008 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 output 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 contactless electronic switch is open when the switching point is reached because the contactless electronic switch takes on the same safe condition if a failure is detected Control lamp for indication of the switching condition e green switch closed e red switch open 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 el Switch open OPTISWITCH 3200 C with contactless electronic switch 21 Setup min mode Dry run protection min mode Dry run protection Failure of the supply voltage min max mode
12. cillator 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 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 contactless electronic switch 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 th
13. d 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 VB6OC contactless electronic switch switch open 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 C with contactless electronic switch 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
14. duit OPTISWITCH 3100 C OPTISWITCH 3200C OPTISWITCH 3300 C mit kontaktlosem Schalter with contactless electronic switch avec sortie lectronique statique VB60C auf das sich diese Erkl rung bezieht mit den folgenden Normen bereinstimmt to which this declaration 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 A1 1998 Klasse A 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 07 07 2004 Supplement Fig 18 CE declaration of conformity OPTISWITCH 3200 C with contactless electronic switch 41 Supplement Manufacturer declaration Manufacturer declaration no 24651 Messrs Krohne S A S Les 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 contactless electronics switch in accordance with DIN EN 60079 14 2004 paragraph 5 2 3 item c 1 and when used correctly under the condition that the operator follows the instructions in the documents listed Mounting and operating instructions in the Operating Instructions manual Data and instructions of this manufacturer declaration installation regulati
15. e 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 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 contactless electronic switch cL L090 N3 9S666 29956 EN 0601 12 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 VB60C The in
16. ed by taking vessel installations and flow conditions in the vessel into account The surface temperature must not exceed the ignition temperature of the concerned explosive atmosphere Single component in the instrument This instrument was judged by a person meeting the requirements acc to DIN EN 60079 14 Krohne S A S Romans Cedex den 31 05 05 J6 o d i V Stengele Fig 19 Manufacturer declaration 42 OPTISWITCH 3200 C with contactless electronic switch cL L090 N3 9S866c 29956 EN 0601 12 OPTISWITCH 3200 C with contactless electronic switch Supplement 43 Subject to change without notice 29956 EN 060112
17. elec tronics are nevertheless switched off reliably Fig 11 Wiring plan 1 Screen OPTISWITCH 3200 C with contactless electronic switch 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 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 Fig 12 Oscillator VB 60C contactless electronic switch Potentiometer for switching point adaptation DIL switch for mode adjustment Ground terminal Terminals Control lamp D P 0 I9 OPTISWITCH 3200 C with contactless electronic switch cL L090 N3 9S666 29956 EN 0601 12 Switching point adaptation 1 Mode adjustment 2 Signal lamp 5 max mode Overfill protection max mode Overfill protection Level Setup With the potentiometer you can adapt the switching point to the solid It is already factory preset and must be adjusted only in spe
18. evice 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 with contactless electronic switch cL L090 N3 9S666 29956 EN 0601 12 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 70 0003 Ibs in 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
19. h 3 About this document Pme V 1 About this document 1 1 Function 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 8 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 contactless electronic switch cL L090 N3 9S666 29956 EN 0601 12 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
20. ing to power supply Note safety instructions Take note of safety instructions for 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 instructions e 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 60C 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 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
21. intenance 24 7 2 Fault rectification SS 24 7 3 Exchanging the electronics 25 7 4 Instrument repair 0 00000 eee 26 8 Dismounting 8 1 Dismounting steps 27 8 2 Disposal llle a 27 OPTISWITCH 3200 C with contactless electronic switch cL L090 N3 9S666 29956 EN 0601 12 Contents 9 Functional safety EE RR ee e A EE sade 28 9 2 Planning 29 93 SEMI sas boa dw EE Geo oS ae ge 31 9 4 Reaction during operation and in case of failure 31 9 5 Recurring function test 5 31 9 6 Safety related characteristics 32 10 Supplement 10 1 Technical data 36 10 2 Dimensions llle 39 10 3 Certificates uu x umb RC ore ee e 41 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 contactless electronic switc
22. ional 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 following 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
23. le 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 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 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 or in case the power supply fails the electronics takes on a defined switching condition i e the contactless electronic switch opens 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 d
24. 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 OPTISWITCH 3200 C with contactless electronic switch cL L090 N3 9S666 29956 EN 0601 12 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 functio
25. nal 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 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 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 50
26. ons 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 operation Measures to maintain the explosion protection during operation This declaration is only applicable if OPTISWITCH is operated within the stated electrical threshold values Permissible operating voltages 20 253 V AC 50 60 Hz 20 253 V DC Imaxz400 mA 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 perfect quality and the correct position of the seal between the lower part of the housing and the cover must be ensured the cover must be screwed on tightly If the instrument is operated with open cover or if the switch potentiometer is used make sure that there is no explosive atmosphere 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 exclud
27. rechend 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 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 la s curit ainsi que les consignes de s curit stipul es dans le Safety Manual sont respecter voir la notice technique de mise en service au chapitre S curit fonctionnelle Romans 21 10 2005 KROHNE S A S L d Dr Florian Stengele Gesch ftsf hrer Managing Director Directeur g n ral Fig 17 SIL declaration of conformity 40 OPTISWITCH 3200 C with contactless electronic switch col L090 N3 9S666 29956 EN 0601 12 CE declaration of conformity LE Konformitatserklarung Declaration of conformity D claration de conformit Krohne S A S Les Ors BP OR F 26103 Romans Cedex erkl rt in alleiniger Verantwortung da3 das Produkt declare under our sole responsibility that our product d clare sous sa seule responsabilit que le pro
28. strument 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 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 10 gt 10 up to 10 gt 10 up to 10 2210 up to 10 gt 10 up to 10 gt 10 up to 107 gt 10 up to 10 OPTISWITCH 3200 C with contactless electronic switch 27 Funct
29. tactless electronic switch 35 Supplement Process conditions Parameter level of solids Process pressure 1 6 bar 100 600 kPa 14 5 87 psi OPTISWITCH 3200 C of 316L 20 80 C 4 176 F Density Standard gt 0 02 g cm 20 0007 Ibs in adjustable 70 008 g cm 20 0003 Ibs in Electromechanical data Cable entry plug dependent on the version Single chamber housing e 1x cable entry M20x1 5 cable 65 9 mm 1x blind stopper M20x1 5 attached 1x cable entry M20x1 5 or e 1x cable entry 2 NPT 1x blind stopper Yo NPT 1x cable entry NPT or e 1x plug M12x1 1x blind stopper M20x1 5 Spring loaded terminals for wire cross section up to 1 5 mm 0 0023 in Adjustment elements Mode switch min min detection or dry run protection max max detection or overfill protection Voltage supply Power supply 20 258 V AC 50 60 Hz 20 253 V DC Domestic current requirement approx 3 mA via load circuit Load current min 10 mA max 400 mA with 300 mA the ambient temper ature can be max 60 C 140 F max 4 A up to 40 ms Electrical protective measures Protection IP 66 IP 67 Overvoltage category Il Protection class 36 OPTISWITCH 3200 C with contactless electronic switch cL L090 N3 9S666 29956 EN 0601 12 Approvals ATEX II 1 2G 2G EEx d IIC T6 ATEX II 1 2 D IP66 T 2 Supplement Deviating data with Ex applications see separ
30. the Ex specific safety information for installation and operation in Ex areas These safety instructions are part of the operating instructions manual and come with the Ex approved instruments OPTISWITCH 3200 C with contactless electronic switch cL L090 N3 9S666 29956 EN 0601 12 Scope of delivery Components Area of application Product description 3 Product description 3 1 Configuration 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 OPTISWITCH 3200 C consists of the following components e Housing cover e Housing with electronics e process fitting with tuning fork 0 OUO 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 OPTISWITCH 3200 C is a level sensor with tuning fork for level detection OPTISWITCH 3200 C with contactless electronic switch 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 simp
31. to the quiescent current principle OPTISWITCH 3200 C with contactless electronic switch 23 Maintenance and fault rectification 24 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 if there is no explosive atmosphere present Proceed as follows k 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 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 contactless electronic switch cL L090 N3 9S666 29956 EN 0601 12 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 os
32. using 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 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 AK 0o l5 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 cL L090 N3 9S666 OPTISWITCH 3200 C with contactless electronic switch 29956 EN 0601 12 Connecting to power supply The contactless electronic switch is always shown in non operative condition The instrument is used for direct control of relays contactors magnet valves warning lights horns etc It must not be operated without an intermediately connected load because the electronics would be destroyed if connected directly to the mains It is not suitable for connection to low voltage PLC inputs The domestic current briefly below 1 mA after switching off the load so that contactors the holding current of which is lower than the permanently flowing domestic current of the
33. 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 OPTISWITCH 3200 C with contactless electronic switch GL L090 N3 9S666 29956 EN 0601 12 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 contactless electronic switch 17 Connecting to power supply 2 Ho
34. ying 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 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 contactless electronic switch cL L090 N3 9S666 29956 EN 0601 12 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 contactless electronic switch 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 contactless electronic switch cL L090 N3 9S666 29956 EN 0601 12 Mounting Fig 7 Baffle protection against damages OPTISWITCH 3200 C with contactless electronic switch 15 Connect
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