KROHNE OPTISWITCH 5250 C (01) PDF MANUAL


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PDF Content Summary: Operating Instructions OPTISWITCH 5200 C, 5250 C - Relay (DPDT) Document ID: 30431 Contents Contents 1 About this document 1.1 Function ........................................................................................................................... 3 1.2 Target group ..................................................................................................................... 3 1.3 Symbols used................................................................................................................... 3 2 For your safety 2.1 Authorised personnel ....................................................................................................... 4 2.2 Appropriate use................................................................................................................ 4 2.3 Warning about incorrect use............................................................................................. 4 2.4 General safety instructions............................................................................................... 4 2.5 Safety label on the instrument .......................................................................................... 5 2.6 CE conformity................................................................................................................... 5 2.7 SIL conformity .................................................................................................................. 5 2.8 Safety instructions for Ex areas ........................................................................................ 5 3 Product description 3.1 Configuration.................................................................................................................... 6 3.2 Principle of operation........................................................................................................ 7 3.3 Operation ......................................................................................................................... 7 3.4 Storage and transport....................................................................................................... 8 4 Mounting 4.1 General instructions ......................................................................................................... 9 4.2 Mounting instructions ..................................................................................................... 12 5 Connecting to power supply 5.1 Preparing the connection ............................................................................................... 15 5.2 Connection procedure.................................................................................................... 15 5.3 Wiring plan, single chamber housing.............................................................................. 16 6 Setup 6.1 General information........................................................................................................ 18 6.2 Adjustment elements...................................................................................................... 18 6.3 Function chart ................................................................................................................ 19 7 Maintenance and fault rectification 7.1 Maintenance .................................................................................................................. 21 7.2 Rectify faults................................................................................................................... 21 7.3 Exchanging the electronics ............................................................................................ 22 7.4 Instrument repair ............................................................................................................ 23 8 Dismount 8.1 Dismounting steps.......................................................................................................... 24 8.2 Disposal ......................................................................................................................... 24 9 Supplement 9.1 Technical data ................................................................................................................ 25 3 9.2 Dimensions .................................................................................................................... 32 0 4 3 1 - E N - 1 4 1 Editing status: 2014-10-08 0 1 5 OPTISWITCH 5200 C, 5250 C • - Relay (DPDT) 2 1 About this document 1 About this document 1.1 Function This operating instructions manual provides all the information you need for mounting, connection and setup as well as important instruc tions for maintenance and fault rectification. Please read this informa tion before putting the instrument into operation and keep this manual accessible in the immediate vicinity of the device. 1.2 Target group This operating instructions manual is directed to trained specialist personnel. The contents of this manual should be made available to these personnel and put into practice by them. 1.3 Symbols used Information, tip, note This symbol indicates helpful additional information. Caution: If this warning is ignored, faults or malfunctions can result. Warning: If this warning is ignored, injury to persons and/or serious damage to the instrument can result. Danger: If this warning is ignored, serious injury to persons and/or destruction of the instrument can result. Ex applications This symbol indicates special instructions for Ex applications. SIL applications This symbol indicates instructions for functional safety which must be taken into account particularly for safety-relevant applications. • List The dot set in front indicates a list with no implied sequence. → Action This arrow indicates a single action. 1 Sequence of actions Numbers set in front indicate successive steps in a procedure. Battery disposal This symbol indicates special information about the disposal of bat teries and accumulators. 5 1 0 1 4 1 - N E - 1 3 4 0 3 OPTISWITCH 5200 C, 5250 C • - Relay (DPDT) 3

2 For your safety 4 2 For your safety 2.1 Authorised personnel All operations described in this operating instructions manual must be carried out only by trained specialist personnel authorised by the plant operator. During work on and with the device the required personal protective equipment must always be worn. 2.2 Appropriate use The OPTISWITCH 5200 C, 5250 C is a sensor for point level detec tion. You can find detailed information about the area of application in chapter "Product description". Operational reliability is ensured only if the instrument is properly used according to the specifications in the operating instructions manual as well as possible supplementary instructions. For safety and warranty reasons, any invasive work on the device beyond that described in the operating instructions manual may be carried out only by personnel authorised by the manufacturer. Arbi trary conversions or modifications are explicitly forbidden. 2.3 Warning about incorrect use 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 This is a state-of-the-art instrument complying with all prevailing regulations and guidelines. The instrument must only be operated in a technically flawless and reliable condition.The operator is responsible for the trouble-free operation of the instrument. During the entire duration of use, the user is obliged to determine the compliance of the necessary occupational safety measures with the current valid rules and regulations and also take note of new regula tions. The safety instructions in this operating instructions manual, the na tional installation standards as well as the valid safety regulations and accident prevention rules must be observed by the user. For safety and warranty reasons, any invasive work on the device beyond that described in the operating instructions manual may be carried out only by personnel authorised by the manufacturer. Arbi trary conversions or modifications are explicitly forbidden. 3 0 The safety approval markings and safety tips on the device must also 4 3 be observed. 1 - E N - 1 4 1 0 1 5 OPTISWITCH 5200 C, 5250 C • - Relay (DPDT)

2 For your safety 2.5 Safety label on the instrument The safety approval markings and safety tips on the device must be observed. 2.6 CE conformity This device fulfills the legal requirements of the applicable EC guide lines. By attaching the CE mark, we provide confirmation of success ful testing. 2.7 SIL conformity OPTISWITCH 5200 C, 5250 C fulfills the requirements on functional safety according to IEC 61508 resp. IEC 61511.You can find further information in the Safety Manual "OPTISWITCH 5XXX". 2.8 Safety instructions for Ex areas Please note the Ex-specific safety information for installation and op eration in Ex areas. These safety instructions are part of the operating instructions manual and come with the Ex-approved instruments. 5 1 0 1 4 1 - N E - 1 3 4 0 3 OPTISWITCH 5200 C, 5250 C • - Relay (DPDT) 5

3 Product description Scope of delivery Constituent parts Type label 6 3 Product description 3.1 Configuration The scope of delivery encompasses: • OPTISWITCH 5200 C, 5250 C point level switch • Documentation – this operating instructions manual – Safety Manual "Functional safety (SIL)" (optional) – Ex-specific "Safety instructions" (with Ex versions) The OPTISWITCH 5200 C, 5250 C consists of the components: • Housing lid • Housing with electronics • Process fitting with tuning fork 1 2 3 Fig. 1: OPTISWITCH 5200 C, 5250 C - with plastic housing 1 Housing lid 2 Housing with electronics 3 Process fitting The type label contains the most important data for identification and use of the instrument: • Article number • Serial number • Technical data • Article numbers, documentation 3 • SIL identification (with SIL rating ex works) 0 4 3 1 In addition to the type label outside on the instrument, you find the - E N serial number also inside the instrument. - 1 4 1 0 1 5 OPTISWITCH 5200 C, 5250 C • - Relay (DPDT)

3 Product description 3.2 Principle of operation

Application area Functional principle Voltage supply 5 1 0 1 4 1 - N E - 1 3 4 0 3 OPTISWITCH 5200 C, 5250 C is a point level sensor with tuning fork for point level detection. It is designed for industrial use in all areas of process technology and can be used in liquids. Typical applications are overfill and dry run protection.With its tuning fork of only 40 mm length, OPTISWITCH 5200 C, 5250 C can also be mounted e.g. in pipelines from DN 32. The small tuning fork allows use in vessels, tanks and pipes. Thanks to its simple and robust measuring system, OPTISWITCH 5200 C, 5250 C is virtually unaf fected by the chemical and physical properties of the liquid. It functions even under difficult conditions such as turbulence, air bub bles, foam generation, buildup, strong external vibration or changing products. Function monitoring The electronics module of OPTISWITCH 5200 C, 5250 C continu ously monitors the following criteria via frequency evaluation: • Strong corrosion or damage on the tuning fork • Loss of vibration • Line break to the piezo drive If a malfunction is detected or in case of power failure, the electron ics takes on a defined switching condition, i.e. the relay deenergises (safe state). The tuning fork is piezoelectrically energised and vibrates at its mechanical resonance frequency of approx. 1200 Hz.The piezos are fixed mechanically and are hence not subject to temperature shock limitations. The frequency changes when the tuning fork is covered by the medium. This change is detected by the integrated electronics module and converted into a switching command. OPTISWITCH 5200 C, 5250 C is a compact instrument, i.e. it can be operated without external evaluation system. The integrated electron ics 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 pump etc.). The data for power supply are specified in chapter "Technical data". 3.3 Operation The switching condition of OPTISWITCH 5200 C, 5250 C with plastic housing can be checked when the housing is closed (signal lamp). With the basic setting, products with a density ≥ 0.7 g/cm³ (0.025 lbs/ in³) can be detected.The instrument can be adapted if products with lower density are to be measured. On the electronics module you will find the following display and adjustment elements: • Signal lamp for indication of the switching condition (green/red) • DIL switch for sensitivity adjustment

OPTISWITCH 5200 C, 5250 C • - Relay (DPDT) 7

3 Product description Packaging Transport Transport inspection Storage Storage and transport temperature 8 • Mode adjustment for selection of the switching condition (A/B) 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 based on ISO 4180. The packaging of standard instruments consists of environment friendly, recyclable carton material. The sensing element is additional ly protected with a cardboard cover. For special versions, PE foam or PE foil is also used. Please dispose of the packaging material through specialised recycling companies. Transport must be carried out in due consideration of the notes on the transport packaging. Nonobservance of these instructions can cause damage to the device. The delivery must be checked for completeness and possible transit damage immediately at receipt. Ascertained transit damage or con cealed defects must be appropriately dealt with. Up to the time of installation, the packages must be left closed and stored according to the orientation and storage markings on the outside. Unless otherwise indicated, the packages must be stored only under the following conditions: • Not in the open • Dry and dust free • Not exposed to corrosive media • Protected against solar radiation • Avoiding mechanical shock and vibration • Storage and transport temperature see chapter "Supplement - Technical data - Ambient conditions" • Relative humidity 20 … 85 % 3 0 4 3 1 - E N - 1 4 1 0 1 5 OPTISWITCH 5200 C, 5250 C • - Relay (DPDT)

4 Mounting 4 Mounting 4.1 General instructions

Suitability for the process conditions Switching point 5 1 0 1 4 1 - N E - 1 3 4 0 3 Make sure that all parts of the instrument coming in direct contact with the process, especially the sensor element, process seal and process fitting, are suitable for the existing process conditions, such as process pressure, process temperature as well as the chemical properties of the medium. You can find the specifications in chapter "Technical data" and on the nameplate. In general, OPTISWITCH 5200 C, 5250 C can be installed in any position. The instrument only has to be mounted in such a way that the tuning fork is at the height of the desired switching point. The tuning fork has lateral markings (notches) that indicate the switching point with vertical mounting. The switching point applies to water in conjunction with the basic setting of the density switch ≥ 0.7 g/cm³ (0.025 lbs/in³).When mounting OPTISWITCH 5200 C, 5250 C, make sure that this marking is at the height of the requested switching point. Keep in mind that the switching point of the instru ment will shift if the medium has a density other than water - water is 1 g/cm³ (0.036 lbs/in³). For products ≤ 0.7 g/cm³ (0.025 lbs/in³) and ≥ 0.5 g/cm³ (0.018 lbs/in³) the density switch must be set to ≥ 0.5 g/ cm³. Keep in mind that foams with a density ≥ 0.45 g/cm³ (0.016 lbs/in³) are detected by the sensor. This can lead to erroneous switchings, particulary when the sensor is used for dry run protection.

OPTISWITCH 5200 C, 5250 C • - Relay (DPDT) 9

4 Mounting 10 2 1 4 3 Fig. 2: Vertical mounting 1 Switching point approx. 13 mm (0.51 in) 2 Switching point with lower density 3 Switching point with higher density 4 Switching point approx. 27 mm (1.06 in) 1 Fig. 3: Horizontal mounting 1 Switching point 2 1 Fig. 4: Horizontal installation (recommended mounting position, particularly for adhesive products) 1 Switching point 2 Marking on top with threaded versions, marking aligned to flange holes with flange versions 3 0 4 With flange versions, the fork is aligned to the flange holes as follows. 3 1 - E N - 1 4 1 0 1 5 OPTISWITCH 5200 C, 5250 C • - Relay (DPDT)

4 Mounting Fig. 5: Fork position with flange versions

Moisture Transport Pressure/Vacuum 5 1 0 1 4 1 - N E - 1 3 4 0 3 Use the recommended cables (see chapter "Connecting to power supply") and tighten the cable gland. You can give your OPTISWITCH 5200 C, 5250 C additional protec tion 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 outdoor mounting as well as installation in areas where high humidity is expected (e.g. through cleaning processes) or on cooled or heated vessels. Fig. 6: Measures against moisture ingress Caution: Do not hold OPTISWITCH 5200 C, 5250 C on the tuning fork. Particu larly with flange or tube versions, the tuning fork can be damaged just by the weight of the instrument. Transport coated instruments very carefully and avoid touching the tuning fork. Remove the packaging or the protective cover just before installation. 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 max. permissible pressure is specified in chapter "Technical data" or on the type label of the sensor.

OPTISWITCH 5200 C, 5250 C • - Relay (DPDT) 11

4 Mounting Handling Welding socket Adhesive products12 The vibrating level switch is a measuring instrument and must be treated accordingly. Bending the vibrating element will destroy the instrument. Warning: The housing must not be used to screw the instrument in! Applying tightening force can damage internal parts of the housing. Use the hexagon above the thread for screwing in. 4.2 Mounting instructions OPTISWITCH 5200 C, 5250 C has a defined thread starting point. This means that every OPTISWITCH 5200 C, 5250 C is in the same fork position after being screwed in. Remove therefore the supplied seal from the thread of OPTISWITCH 5200 C, 5250 C. This seal is not required when using a welded socket with O-ring in front. Keep in mind that this welded socket is not suitable for coated instru ment versions. Screw OPTISWITCH 5200 C, 5250 C completely into the welded socket. The later position can be determined already before welding. Mark the appropriate position of the welded socket. Before welding, unscrew OPTISWITCH 5200 C, 5250 C and remove the rubber ring from the welded socket. The welded socket has a marking (notch). Weld the socket with the notch facing upward, or in case of pipelines (DN 32 up to DN 50), aligned with the direction of flow. 1 Fig. 7: Marking on the welded socket 1 Marking In case of horizontal mounting in adhesive and viscous products, the surfaces of the tuning fork should be vertical in order to reduce buildup on the tuning fork. On the screwed version you will find a marking on the hexagon. With this you can check the position of the tuning fork when screwing it in. When the hexagon touches the seal, the thread can still be turned by approx. half a turn.This is sufficient to reach the recommended installation position. In the case of flange versions, the fork is aligned with the flange holes. 3 0 When used in adhesive and viscous products, the tuning fork should 4 3 protrude into the vessel to avoid buildup. For that reason, sockets 1 - E for flanges and mounting bosses should be avoided when mounting N horizontally. - 1 4 1 0 1 5 OPTISWITCH 5200 C, 5250 C • - Relay (DPDT)

Inflowing medium Product flow Agitators 5 1 0 1 4 1 - N E - 1 3 4 0 3 4 Mounting If OPTISWITCH 5200 C, 5250 C is mounted in the filling stream, un wanted false measurement signals can be generated. For this reason, mount OPTISWITCH 5200 C, 5250 C at a position in the vessel where no disturbances, e.g. from filling openings, agitators, etc., can occur. This applies particularly to instrument types with long extension tube. Fig. 8: Inflowing medium To make sure the tuning fork of OPTISWITCH 5200 C, 5250 C gener ates as little resistance as possible to product flow, mount the sensor so that the surfaces are parallel to the product movement. Due to agitators, vibrations or similar, the level switch can be sub jected to strong lateral forces. For this reason, do not use an overly long extension tube for OPTISWITCH 5200 C, 5250 C, but check if you can mount an OPTISWITCH 5100 C, 5150 C level switch on the side of the vessel in horizontal position. Extreme vibration caused by the process or the equipment, e.g. agitators or turbulence in the vessel, can cause the extension tube of OPTISWITCH 5200 C, 5250 C to vibrate in resonance. This leads to increased stress on the upper weld joint. Should a longer tube version be necessary, you can provide a suitable support directly above the tuning fork to secure the extension tube. This measure applies mainly to applications in Ex areas category 1G or WHG. Make sure that the tube is not subject to bending stress due to this measure.

OPTISWITCH 5200 C, 5250 C • - Relay (DPDT) 13

4 Mounting Enamel coating Gas-tight leadthrough14 Fig. 9: Lateral suppot of OPTISWITCH 5200 C, 5250 C Instruments with enamel coating should be treated very carefully and shocks should be avoided. Unpack OPTISWITCH 5200 C, 5250 C directly before installation. Insert OPTISWITCH 5200 C, 5250 C carefully into the vessel opening and avoid touching any sharp vessel parts. The second seal of the gas-tight leadthrough (option) prevents an uncontrolled leakage of the medium. The service life of the gas-tight leadthrough depends on the chemical resistance of the materials. See "Technical data". Caution: If it is determined (e.g. via an error message from OPTISWITCH 5200 C, 5250 C) that medium has already penetrated into the vibrating ele ment, the instrument must be exchanged immediately. 3 0 4 3 1 - E N - 1 4 1 0 1 5 OPTISWITCH 5200 C, 5250 C • - Relay (DPDT)

Note safety instructions Take note of safety instructions for Ex applications Voltage supply Connection cable Connection cable for Ex applications 5 1 0 1 4 1 - N E - 1 3 4 0 3 5 Connecting to power supply 5 Connecting to power supply 5.1 Preparing the connection Always keep in mind the following safety instructions: Warning: Connect only in the complete absence of line voltage. • The electrical connection must only be carried out by trained personnel authorised by the plant operator. • Always switch off power supply, before connecting or disconnect ing the instrument. In hazardous areas you must take note of the respective regulations, conformity and type approval certificates of the sensors and power supply units. Connect the voltage supply according to the connection diagrams. The electronics module with relay output is designed in protection class I. To maintain this protection class, it is absolutely necessary that the earth conductor be connected to the inner earth conductor terminal. Keep the general installation regulations in mind. Take note of the corresponding installation regulations for hazardous areas with Ex applications. The data for power supply are specified in chapter "Technical data". The instrument is connected with standard three-wire cable without screen. If electromagnetic interference is expected which is above the test values of EN 61326 for industrial areas, screened cable should be used. Use cable with round cross-section. A cable outer diameter of 5 … 9 mm (0.2 … 0.35 in) ensures the seal effect of the cable gland. If you are using cable with a different diameter or cross-section, exchange the seal or use a suitable cable gland. In hazardous areas, use only approved cable connections for OPTIS WITCH 5200 C, 5250 C. Take note of the corresponding installation regulations for Ex applica tions. Cover all housing openings conforming to standard according to EN 60079-1. 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 gland 3. Remove approx. 10 cm (4 in) of the cable mantle, strip approx. 1 cm (0.4 in) of insulation from the ends of the individual wires 4. Insert the cable into the sensor through the cable entry

OPTISWITCH 5200 C, 5250 C • - Relay (DPDT) 15

5 Connecting to power supply Housing overview 5. Open the terminals with a screwdriver 6. Insert the wire ends into the open terminals according to the wir ing plan 7. Tighten the terminals with a screwdriver 8. Check the hold of the wires in the terminals by lightly pulling on them 9. Tighten the compression nut of the cable entry gland. The seal ring must completely encircle the cable 10. Screw the housing lid back on The electrical connection is finished. 5.3 Wiring plan, single chamber housing The following illustrations apply to the non-Ex as well as to the Ex-d version. 4 4 4

1 2 3 Fig. 10: Material versions, single chamber housing 1 Plastic (not with EEx d) 2 Aluminium 3 Stainless steel (not with EEx d) 4 Filter element for pressure compensation (not with EEx d) 3 0 4 3 1 - E N - 1 4 1 0 1 5 OPTISWITCH 5200 C, 5250 C • - Relay (DPDT) 16 5 Connecting to power supply Electronics and terminal compartment SW E60R

3 4 5 6 7 8 20-72V DC 20-250V A C + A 0,5 g / cm3 0,7 g / cm3 1 2

B L N 3 1 2 3 4 5 6 7 8 4 5

Wiring plan Fig. 11: Electronics and terminal compartment, single chamber housing 1 Control lamp 2 DIL switch for mode adjustment 3 DIL switch for switching point adaptation 4 Ground terminal 5 Connection terminals We recommend connecting OPTISWITCH 5200 C, 5250 C in such a way that the switching circuit is open when there is a level signal, line break or failure (safe state). Information: The relays are always shown in non-operative condition. +L1 -N 1 2 3 4 5 6 Fig. 12: Wiring plan, single chamber housing 1 Relay output 2 Relay output 3 Voltage supply 5 1 0 1 4 1 - N E - 1 3 4 0 3 OPTISWITCH 5200 C, 5250 C • - Relay (DPDT) 7 8 1 2 3 17 6 Setup Function/Configuration 6 Setup 6.1 General information The figures in brackets refer to the following illustrations. With plastic housings, the switching condition of the electronics can be checked when the housing cover is closed (control lamp). With the basic setting, products with a density ≥ 0.7 g/cm³ (0.025 lbs/in³) can be detected. For products with lower density, the switch must be set to ≥ 0.5 g/cm³ (0.018 lbs/in³). On the electronics module you will find the following display and adjustment elements: • Signal lamp (1) • DIL switch for mode adjustment - A/B (2) • DIL switch for sensitivity adjustment (3) Note: Always immerse the tuning fork of OPTISWITCH 5200 C, 5250 C in a liquid to test its function. Do not test the function of OPTISWITCH 5200 C, 5250 C with your hand. This can damage the sensor. 6.2 Adjustment elements 1 2

2 1 8 7 6 5 4 3 3

Signal lamp (1) Mode adjustment (2)18 Fig. 13: Oscillator SWE60R - Relay output 1 Control lamp (LED) 2 DIL switch for mode adjustment 3 DIL switch for sensitivity adjustment Control lamp for indication of the switching status • green = relay energized • red = relay deenergized 3 0 • red (flashing) = failure 4 3 1 - E N With the mode adjustment (A/B) you can change the switching - 1 condition of the relay. You can set the required mode according to the 4 1 0 1 5 OPTISWITCH 5200 C, 5250 C • - Relay (DPDT)

Sensitivity adjustment (3) 6 Setup "Function chart" (A - max. detection or overflow protection, B - min. detection or dry run protection). With this DIL switch (3) you can set the switching point to liquids having a density between 0.5 and 0.7 g/cm³ (0.018 and 0.025 lbs/ in³).With the basic setting, liquids with a density of ≥ 0.7 g/cm³ (0.025 lbs/in³) can be detected. In liquids with lower density, you must set the switch to ≥ 0.5 g/cm³ (0.018 lbs/in³).The specifications for the position of the switching point relate to water - density value 1 g/cm³ (0.036 lbs/in³). In products with a different density, the switching point will shift in the direction of the housing or tuning fork end depending on the density and type of installation. Note: Keep in mind that foams with a density ≥ 0.45 g/cm³ (0.016 lbs/in³) are detected by the sensor. This can lead to erroneous switchings, particulary when the sensor is used for dry run protection. 6.3 Function chart The following chart provides an overview of the switching conditions depending on the set mode and the level. Level Switching status Control lamp Mode A Overflow protection 3 4 5 (6) (7) (8) Relay energized Green Mode A Overflow protection 3 4 5 (6) (7) (8) Relay deenergized Red Mode B Dry run protection 3 4 5 (6) (7) (8) Relay energized Green Mode B Dry run protection 3 4 5 (6) (7) (8) Relay deenergized Red Failure of the supply voltage (mode A/B) 5 1 0 1 4 1 - N E - 1 3 4 0 3 OPTISWITCH 5200 C, 5250 C • - Relay (DPDT) any 3 4 5 (6) (7) (8) Relay deenergized 19

6 Setup 20 Level Switching status Control lamp Fault any 3 4 5 (6) (7) (8) Relay deenergized flashes red 3 0 4 3 1 - E N - 1 4 1 0 1 5 OPTISWITCH 5200 C, 5250 C • - Relay (DPDT)

Reaction when malfunc tions occur Causes of malfunction Fault rectification 5 1 0 1 4 1 - N E - 1 3 4 0 3 7 Maintenance and fault rectification 7 Maintenance and fault rectification 7.1 Maintenance If the instrument is used properly, no special maintenance is required in normal operation. 7.2 Rectify faults The operator of the system is responsible for taking suitable meas ures to rectify faults. OPTISWITCH 5200 C, 5250 C offers maximum reliability. Neverthe less, faults can occur during operation. These may be caused by the following, e.g.: • Sensor • Process • Voltage supply • Signal processing The first measure to take is to check the output signal. In many cases, the causes can be determined this way and the faults quickly rectified.

21 OPTISWITCH 5200 C, 5250 C • - Relay (DPDT) 7 Maintenance and fault rectification Checking the switching

signal Error Cause Rectification

OPTISWITCH 5200 C, 5250 C signals "cov Operating voltage too low Check operating voltage

ered" without being submerged (overfill pro tection) OPTISWITCH 5200 C, 5250 C signals "un covered" when being submerged (dry run pro tection) Electronics defective Press the mode switch. If the instrument then changes the mode, the vibrating element may be covered with buildup or mechanically damaged. Should the switching function in the correct mode still be faulty, re turn the instrument for repair. Press the mode switch. If the instrument then does not change the mode, the electronics module may be defective. Ex change the electronics module.

Unfavourable installation location Buildup on the vibrating element Mount the instrument at a location in the vessel where no dead zones or air bubbles can form. Check the vibrating ele ment and the sensor for buildup and remove the buildup if there is any.

Wrong mode selected Set the correct mode with the mode switch (overflow protection, dry run protection). Wir ing should be carried out according to the closed circuit principle.

Signal lamp flashes red Error on the vibrating el ement Interference on the elec tronics module Check if the vibrating el ement is damaged or extremely corroded. Exchanging the electron ics module

Reaction after fault recti fication 22 instrument defective Exchange the instrument or send it in for repair Depending on the reason for the fault and the measures taken, the steps described in chapter "Set up" may have to be carried out again. 3 0 7.3 Exchanging the electronics 4 3 1 If the electronics module is defective, it can be replaced by the user. - E N In Ex applications only an electronics module with respective Ex ap - 1 proval may be used. 4 1 0 1 5 OPTISWITCH 5200 C, 5250 C • - Relay (DPDT)

7 Maintenance and fault rectification You can find all the information you need to carry out an electronics exchange in the handbook of the new electronics module. In general, all electronics modules of series SW60 can be inter changed. If you want to use an electronics module with a different signal output, you carry out the complete setup.You find the neces sary, suitable operating instruction on our homepage. Note: Keep in mind that enamelled instrument versions need special electronics modules. These electronics modules are called SW60E or SW60E1. 7.4 Instrument repair If a repair is necessary, please proceed as follows: On our homepage in the Internet under krohne-mar.com/fileadmin/ media-lounge/PDF-Download/Specimen_e.pdf you can download a return form. By doing this you help us carry out the repair quickly and without hav ing to call back for needed information. • Print and fill out one form per instrument • Clean the instrument and pack it damage-proof • Attach the completed form and possibly also a safety data sheet to the instrument 5 1 0 1 4 1 - N E - 1 3 4 0 3 OPTISWITCH 5200 C, 5250 C • - Relay (DPDT) 23

8 Dismount 24 8 Dismount 8.1 Dismounting steps Warning: Before dismounting, be aware of dangerous process conditions 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 The instrument consists of materials which can be recycled by spe cialised recycling companies. We use recyclable materials and have designed the parts 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. Pass the instrument directly on to a spe cialised recycling company and do not use the municipal collecting points. These may be used only for privately used products according to the WEEE directive. Correct disposal avoids negative effects on humans and the environ ment and ensures recycling of useful raw materials. Materials: see chapter "Technical data" If you have no way to dispose of the old instrument properly, please contact us concerning return and disposal. 3 0 4 3 1 - E N - 1 4 1 0 1 5 OPTISWITCH 5200 C, 5250 C • - Relay (DPDT)

9 Supplement 9 Supplement 9.1 Technical data General data Material 316L corresponds to 1.4404 or 1.4435 Materials, wetted parts Ʋ Process fitting - thread 316L, Alloy C22 (2.4602) Ʋ Process fitting - flange 316L, 316L with Alloy C22 coating, steel enamelled, 316L with ECTFE coating, 316L with PFA coating Ʋ Process seal Klingersil C-4400 Ʋ Tuning fork 316L, Alloy C22 (2.4602) Ʋ Extension tube: ø 21.3 mm (0.839 in) 316L, Alloy C22 (2.4602), Alloy C22 (2.4602) enamelled, 316L with ECTFE coating, 316L with PFA coating Materials, non-wetted parts Ʋ Housing Plastic PBT (polyester), Alu die-casting powder-coated, 316L

Ʋ Seal between housing and housing cover NBR (stainless steel housing), silicone (Alu/plastic hous ing)

Ʋ Optical fibre in housing cover PMMA (Makrolon) Ʋ Ground terminal 316L Ʋ Temperature adapter (optional) 316L Gas-tight leadthrough (optional) Ʋ Supporting material 316L Ʋ Glass potting Borosilicate glass - Schott no. 8421 Ʋ Contacts 1.4101 Ʋ Helium leak rate < 10-6 mbar l/s Ʋ Pressure resistance PN 64 Lengths Ʋ 316L, Alloy C22 (2.4602) 80 … 6000 mm (3.15 … 236.22 in) Ʋ Alloy C22 (2.4602) enamelled 80 … 1500 mm (3.15 … 59.055 in) Ʋ 316L, ECTFE coated 80 … 3000 mm (3.15 … 118.11 in) Ʋ 316L, PFA coated 80 … 4000 mm (3.15 … 157.48 in) Tube diameter ø 21.3 mm (0.839 in) Weight Ʋ Plastic housing 760 g (27 oz) Ʋ Aluminium housing 1170 g (41 oz) Ʋ Stainless steel housing 1530 g (54 oz) Ʋ Tube extension approx. 920 g/m (9.9 oz/ft) 5 Layer thickness 1 0 1 Ʋ Enamel approx. 0.8 mm (0.031 in) 4 1 - Ʋ ECTFE approx. 0.5 mm (0.02 in) N E - Ʋ PFA approx. 0.5 mm (0.02 in) 1 3 4 0 3 25 OPTISWITCH 5200 C, 5250 C • - Relay (DPDT) 9 Supplement Surface quality Ʋ Standard Ra approx. 3 µm (1.18-4 in)

Ʋ Hygienic version 3A (OPTISWITCH 5250 C) Ʋ Hygienic version 3A (OPTISWITCH 5250 C) Process fittings Ra < 0.8 µm (3.15-5 in) Ra < 0.3 µm (1.18-5 in)

Ʋ Pipe thread, cylindrical (DIN 3852-A) G¾ A, G1 A

Ʋ American pipe thread, conical (ASME B1.20.1) ¾ NPT or 1 NPT

Ʋ Flanges DIN from DN 25, ANSI from 1" Ʋ hygienic fittings Slotted nut DN 40 PN 40, Clamp 1" DIN 32676 ISO 2852/316L, Clamp 2" DIN 32676 ISO 2852/316L, conus DN 25 PN 40, Tuchenhagen Varivent DN 50 PN 10 Max. torque - process fitting Ʋ Thread G¾ A, ¾ NPT 75 Nm (55 lbf ft) Ʋ Thread G1 A, 1 NPT 100 Nm (73 lbf ft) High voltage test (enamel) max. 5 KV Gas-tight leadthrough (optional) Ʋ Leakage rate < 10-6 mbar l/s Ʋ Pressure resistance PN 64 Output variable Output Relay output (DPDT), 2 floating spdts Switching voltage Ʋ Min. 10 mV Ʋ Max. 253 V AC, 253 V DC Switching current Ʋ Min. 10 µA Ʋ Max. 3 A AC, 1 A DC Breaking capacity Ʋ Min. 50 mW Ʋ Max. 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. Contact material (relay contacts) AgNi (Au plated) or AgSnO (Au plated) 3 0 Modes (switchable) 4 3 Ʋ A Max. detection or overflow/overfill protection 1 - E Ʋ B Min. detection or dry run protection N - 1 4 1 0 1 5 OPTISWITCH 5200 C, 5250 C • - Relay (DPDT) 26 9 Supplement Accuracy (according to DIN EN 60770-1) Reference conditions and actuating variables according to DIN EN 61298-1 Ʋ Ambient temperature +18 … +30 °C (+64 … +86 °F) Ʋ Relative humidity 45 … 75 % Ʋ Air pressure 860 … 1060 mbar/86 … 106 kPa (12.5 … 15.4 psig) Ʋ Product temperature +18 … +30 °C (+64 … +86 °F) Ʋ Product density 1 g/cm³ (0.036 lbs/in³) (water) Ʋ Product viscosity 1 mPa s Ʋ Superimposed pressure 0 kPa Ʋ Sensor installation Vertically from top Ʋ Density selection switch ≥ 0.7 g/cm³ Measuring accuracy Deviation ± 1 mm (0.04 in) Influence of the process temperature on the switching point 1

4 3 2 10 ( 25/64") 8 ( 5/16") 6 ( 15/64") 4 ( 5/32") 2 ( 5/64") 0 -2 (-5/64")

-4 (-5/32") -6 (-15/64") -8 (-5/16") -10 (-25/64") 0 °C (32 °F) 50 °C (122 °F) 100 °C (212 °F) 150 °C (302 °F) 200 °C (392 °F) 250 °C (482 °F)

Fig. 30: Influence of the process temperature on the switching point 1 Shifting of the switching point in mm (in) 2 Process temperature in °C (°F) 3 Switching point at reference conditions (notch) 4 Tuning fork 5 1 0 1 4 1 - N E - 1 3 4 0 3 OPTISWITCH 5200 C, 5250 C • - Relay (DPDT) 27 9 Supplement Influence of the product density on the switching point 1

6 5 10 ( 25/64") 8 ( 5/16") 6 ( 15/64") 4 ( 5/32") 2 ( 5/64") 0 -2 (-5/64") -4 (-5/32") -6 (-15/64") -8 (-5/16") -10 (-25/64") 2 4 3

0,6 (0,022) 0,8 (0,029) 1 (0,036) 1,2 (0,043) 1,4 (0,051) 1,6 (0,058) 1,8 (0,065) 2 (0,072) 2,2 (0,079) 2,4 (0,087)

Fig. 31: Influence of the product density on the switching point 1 Shifting of the switching point in mm (in) 2 Product density in g/cm³ (lb/in³) 3 Switch position ≥ 0.5 g/cm³ (0.018 lb/in³) 4 Switch position ≥ 0.7 g/cm³ (0.025 lb/in³) 5 Switching point at reference conditions (notch) 6 Tuning fork Influence of the process pressure to the switching point 1

4 3 12 (174,1) 10 ( 25/64") 8 ( 5/16") 6 ( 15/64") 4 ( 5/32") 2 ( 5/64") 0 -2 (-5/64") -4 (-5/32") -6 (-15/64") -8 (-5/16") -10 (-25/64") 25 (362,6) 38 (551,1) 51 (739,7) 2 64 (928,2)

Fig. 32: Influence of the process pressure to the switching point 1 Shifting of the switching point in mm (in) 2 Process pressure in bar (psig) 3 Switching point at reference conditions (notch) 4 Tuning fork Repeatability 0.1 mm (0.004 in) 3 0 4 Hysteresis approx. 2 mm (0.08 in) with vertical installation 3 1 - Switching delay approx. 500 ms (on/off) E N - Measuring frequency approx. 1200 Hz 1 4 1 0 1 5 OPTISWITCH 5200 C, 5250 C • - Relay (DPDT) 28 9 Supplement Ambient conditions Ambient temperature on the housing -40 … +70 °C (-40 … +158 °F) Storage and transport temperature -40 … +80 °C (-40 … +176 °F) Process conditions Measured variable Limit level of liquids Process pressure -1 … 64 bar/-100 … 6400 kPa (-14.5 … 928 psig) The process pressure is dependent on the process fitting, for example Clam p or flange (see the following diagrams) Maximum allowable operating pressure 100 bar/10000 kPa (1450 psig) or 1.5 times process pressure The function of the instrument is ensured up to an operating pressure of 100 bar/10000 kPa (1450 psig) at a maximum process temperature of +50 °C (+122 °F) (only with threaded versions). Process temperature (thread or flange temperature)

Ʋ OPTISWITCH 5200 C, 5250 C of 316L/Alloy C22 (2.4602) Process temperature (thread or flange temperature) with temperature adapter (option) Ʋ OPTISWITCH 5200 C, 5250 C of 316L/Alloy C22 (2.4602) Ʋ OPTISWITCH 5200 C, 5250 C enam elled Ʋ OPTISWITCH 5200 C, 5250 C with ECTFE coating Ʋ OPTISWITCH 5200 C, 5250 C with PFA coating -50 … +150 °C (-58 … +302 °F) -50 … +250 °C (-58 … +482 °F) -50 … +200 °C (-58 … +392 °F) -50 … +150 °C (-58 … +302 °F) -50 … +250 °C (-58 … +482 °F)

23 70 °C (158 °F) 40 °C (104 °F) 1 0 °C

-50 °C (-58 °F) (32 °F) -40 °C (-40 °F) 50 °C (122 °F) 100 °C (212 °F) 150 °C (302 °F) 200 °C (392 °F) 250 °C (482 °F)

Fig. 33: Ambient temperature - Process temperature 5 1 1 Process temperature in °C (°F) 0 1 2 Ambient temperature in °C (°F) 4 1 - 3 Temperature range with temperature adapter N E - 1 3 4 0 3 OPTISWITCH 5200 C, 5250 C • - Relay (DPDT) 29 9 Supplement 1 64 (928) 40 (580) 20 (290) -1 (-14,5) 2 -50 °C

(-58 °F) 0 °C (32 °F) 50 °C (122 °F) 100 °C (212 °F) 150 °C (302 °F) 200 °C (392 °F) 250 °C (482 °F)

Fig. 34: Process temperature - Process pressure with switch position ≥ 0.7 g/cm³ (sensitivity switch) 1 Process pressure in bar (psig) 2 Process temperature in °C (°F) 1 64 (928) 40 (580) 20 (290) -1 (-14,5) 2 -50 °C

(-58 °F) 0 °C (32 °F) 50 °C (122 °F) 100 °C (212 °F) 150 °C (302 °F) 200 °C (392 °F) 250 °C (482 °F)

Fig. 35: Process temperature - Process pressure with switch position ≥ 0.5 g/cm³ (sensitivity switch) 1 Process pressure in bar (psig) 2 Process temperature in °C (°F) Viscosity - dynamic 0.1 … 10000 mPa s (requirement: with density 1) Flow velocity max. 6 m/s (with a viscosity of 10000 mPa s) Density 0.7 … 2.5 g/cm³ (0.025 … 0.09 lbs/in³); 0.5 … 2.5 g/cm³ (0.018 … 0.09 lbs/in³) by switching over Vibration resistance Ʋ Instrument housing 1 g at 5 … 200 Hz according to EN 60068-2-6 (vibration with resonance) Ʋ Sensor 1 g with 5 … 200 Hz according EN 60068-2-6 (vibration at resonance) with sensor length up to 50 cm (19.69 in) With a sensor length > 50 cm (19.69 in) you have to fix the extension tube with a suitable support. See mounting instructions. 3 0 4 3 1 - E N - 1 4 1 0 1 5 OPTISWITCH 5200 C, 5250 C • - Relay (DPDT) 30 9 Supplement Electromechanical data Cable entry/plug (dependent on the version) Ʋ Single chamber housing – 1 x cable entry M20 x 1.5 (cable: ø 5 … 9 mm), 1 x blind plug M20 x 1.5; attached 1 x cable entry M20 x 1.5 or: – 1 x cable entry ½ NPT, 1 x blind plug ½ NPT, 1 x cable entry ½ NPT or: – 1 x plug M12 x 1; 1 x blind plug M20 x 1.5 Screw terminals for wire cross-section up to 1.5 mm² (AWG 16) Adjustment elements Mode switch Ʋ A Max. detection or overflow/overfill protection Ʋ B Min. detection or dry run protection Density changeover switch Ʋ ≥ 0.5 g/cm³ 0.5 … 2.5 g/cm³ (0.018 … 0.9 oz/in³) Ʋ ≥ 0.7 g/cm³ 0.7 … 2.5 g/cm³ (0.025 … 0.9 oz/in³) Voltage supply Operating voltage 20 … 253 V AC, 50/60 Hz, 20 … 72 V DC (at U >60 V DC, the ambient temperature can be max. 50 °C/122 °F) Power consumption 1 … 8 VA (AC), approximately 1.5 W (DC) Electrical protective measures Protection rating IP 66/IP 67 (NEMA 4X) Overvoltage category III Protection class I Approvals Depending on the version, instruments with approvals can have different technical data. For these instruments, please note the corresponding approval documents. They are included in the scope of delivery. 5 1 0 1 4 1 - N E - 1 3 4 0 3 OPTISWITCH 5200 C, 5250 C • - Relay (DPDT) 31

9 Supplement 9.2 Dimensions OPTISWITCH 5200 C, 5250 C ~ 69mm (2 23/32") ø 77mm (3 1/32") ) " m 2 3 / m 3 2 1 1 4 1 ( ~ 69mm (2 23/32") ~ 116mm (4 9/16") ø 77mm (3 1/32") ø 84mm (3 5/16") ) ) " " m 4 m 4 6 / 6 m / m 9 7 1 3 4 3 1 1 4 1 4 ( 1 ( M20x1,5/

M20x1,5/ M20x1,5 ½ NPTM20x1,5/

½ NPT ½ NPT

1 2 3 Fig. 36: Housing versions 1 Plastic housing 2 Stainless steel housing 3 Aluminium housing 3 0 4 3 1 - E N - 1 4 1 0 1 5 OPTISWITCH 5200 C, 5250 C • - Relay (DPDT) 32 9 Supplement OPTISWITCH 5200 C, 5250 C

m m 5, 81 ) " 3 7. 0( 32 (G3/4A, 3/4"NPT) 41 (G1A, 1"NPT) G3/4A, 3/4"NPT G1A, 1"NPT ø 21,3 mm (0.84") m m 63 ) " 2 4 . 1 ( m m 7 5 ) " 4 2. 2(

1 2 3 L

m m 9 1 )ø 33,7 mm L ) " 5 7 . 0 ( L )

m m 05 (1.33") " m " 7 7 m 9 9 . . 0 1 1 ( ( 5 6 4 5

LL L Fig. 37: OPTISWITCH 5200 C, 5250 C, threaded version 1 Thread 2 Clamp 3 Cone DN 25 4 Slotted nut DN 40 5 Flange 6 Tuchenhagen Varivent L = Sensor length, see chapter "Technical data" 5 1 0 1 4 1 - N E - 1 3 4 0 3 OPTISWITCH 5200 C, 5250 C • - Relay (DPDT) 33

9 Supplement OPTISWITCH 5200 C, 5250 C, options ) ) " 1 0 . 7 ( m m 8 7 1 1 2

m " 4 m 3 . 4 1 ( 3 Fig. 38: Options 1 Gas-tight leadthrough 2 Temperature adapter 34 3 0 4 3 1 - E N - 1 4 1 0 1 5 OPTISWITCH 5200 C, 5250 C • - Relay (DPDT)

5 1 0 1 4 1 - N E - 1 3 4 0 3 OPTISWITCH 5200 C, 5250 C • - Relay (DPDT) Notes 35

Subject to change without notice 30431-EN-141015


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