Operating Instructions - Fagerberg

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Operating Instructions - Fagerberg

ContentsContents1 About this document1.1 Function ............................. 51.2 Target group .......................... 51.3 Symbolism used ....................... 52 For your safety2.1 Authorised personnel .................... 62.2 Appropriate use. ....................... 62.3 Warning about misuse ................... 62.4 General safety instructions ................ 62.5 CE conformity ......................... 62.6 SIL conformity ......................... 72.7 Safety information for Ex areas. ............ 73 Product description3.1 Configuration. ......................... 83.2 Principle of operation .................... 83.3 Adjustment ........................... 93.4 Storage and transport ................... 104 Mounting4.1 General instructions ..................... 114.2 Mounting information .................... 125 Connecting to power supply5.1 Preparing the connection ................. 155.2 Connection procedure ................... 155.3 Wiring plans, signal chamber housing ........ 166 Setup6.1 General. ............................. 196.2 Adjustment elements .................... 196.3 Function chart ......................... 206.4 Recurring function test ................... 217 Maintenance and fault rectification7.1 Service .............................. 247.2 Fault rectification ....................... 247.3 Exchanging the electronics. ............... 257.4 Instrument repair ....................... 278 Dismounting8.1 Dismounting steps ...................... 282 OPTISWITCH 3100 C - with NAMUR output31356-EN-051207

Contents8.2 Disposal ............................. 289 Functional safety9.1 General. ............................. 299.2 Planning ............................. 309.3 Setup ............................... 329.4 Reaction during operation and in case of failure. 339.5 Recurring function test ................... 339.6 Safety-related characteristics .............. 3410 Supplement10.1 Technical data. ........................ 3710.2 Dimensions ........................... 4110.3 Certificates ........................... 44Supplementary operating instructions manualsInformation:OPTISWITCH 3100 C is available in different versions.Depending on the selected version, supplementary operatinginstructions manuals will also be included in the scope ofdelivery. The supplementary operating instructions manualsare listed in section "Product description".31356-EN-051207Operating instructions manuals for accessories andreplacement partsTip:We offer accessories and replacement parts to enable reliableuse and operation of your OPTISWITCH 3100 C. Thecorresponding operating instructions manuals are:lOperating instructions manual "Oscillator"OPTISWITCH 3100 C - with NAMUR output 3

About this document1 About this document1.1 FunctionThis operating instructions manual has all the information youneed for quick setup and safe operation of OPTISWITCH 3100C. Please read this manual before you start setup.1.2 Target groupThis operating instructions manual is directed to trainedpersonnel. The contents of this manual should be madeavailable to these personnel and put into practice by them.1.3 Symbolism usedInformation, tip, noteThis symbol indicates helpful additional information.Caution, warning, dangerThis symbol informs you of a dangerous situation that couldoccur. Ignoring this cautionary note can impair the person and/or the instrument.Ex applicationsThis symbol indicates special instructions for Ex applications.làListThe dot set in front indicates a list with no implied sequence.ActionThis arrow indicates a single action.1 SequenceNumbers set in front indicate successive steps in a procedure.4 OPTISWITCH 3100 C - with NAMUR output31356-EN-051207

For your safety2 For your safety2.1 Authorised personnelAll operations described in this operating instructions manualmust be carried out only by trained and specialist personnelauthorised by the operator. For safety and warranty reasons,any internal work on the instruments must be carried out onlyby personnel authorised by the manufacturer.2.2 Appropriate useOPTISWITCH 3100 C is a sensor for level detection.Detailed information on the application range of OPTISWITCH3100 C is available in chapter "Product description".2.3 Warning about misuseInappropriate or incorrect use of the instrument can give rise toapplication-specific hazards, e.g. vessel overfill or damage tosystem components through incorrect mounting or adjustment.2.4 General safety instructionsOPTISWITCH 3100 C is a high-tech instrument requiring thestrict observance of standard regulations and guidelines. Theuser must take note of the safety instructions in this operatinginstructions manual, the country-specific installation standards(e.g. the VDE regulations in Germany) as well as all prevailingsafety regulations and accident prevention rules.2.5 CE conformityOPTISWITCH 3100 C is in CE conformity with EMC (89/336/EWG), fulfils the NAMUR recommendation NE 21 and is in CEconformity with NSR (73/23/EWG).Conformity has been judged acc. to the following standards:31356-EN-051207lEMC:- Emission EN 61326: 1997 (class B)- Susceptibility EN 61326: 1997/A1: 1998l LVD: EN 61010-1: 2001OPTISWITCH 3100 C - with NAMUR output 5

For your safety2.6 SIL conformityOPTISWITCH 3100 C fulfills the requirements for functionalsafety acc. to IEC 61508. You will find further information inchapter "Functional safety".2.7 Safety information for Ex areasPlease note the Ex-specific safety information for installationand operation in Ex areas. These safety instructions are part ofthe operating instructions manual and come with the Exapprovedinstruments.6 OPTISWITCH 3100 C - with NAMUR output31356-EN-051207

Product description3 Product description3.1 ConfigurationScope of deliveryComponentsThe scope of delivery encompasses:llOPTISWITCH 3100 C level sensorDocumentation- this operating instructions manual- Supplementary instructions manual "Plug connector forlevel sensors" - optional- Ex specific safety instructions (with Ex versions), ifnecessary further certificatesOPTISWITCH 3100 C consists of the following components:lllHousing coverHousing with electronicsprocess fitting with tuning fork123Fig. 1: OPTISWITCH 3100 C - with plastic housing1 Housing cover2 Housing with electronics3 Process fitting3.2 Principle of operation31356-EN-051207Area of applicationOPTISWITCH 3100 C is a level sensor with tuning fork for leveldetection.It is designed for industrial use in all areas of processtechnology and is preferably used for bulk solids.Typical applications are overfill and dry run protection. Thanksto its simple and robust measuring system, OPTISWITCH3100 C is virtually unaffected by the chemical and physicalproperties of the solid.OPTISWITCH 3100 C - with NAMUR output 7

Product descriptionIt functions even when exposed to strong external vibration orchanging products.Solid detection in waterIf OPTISWITCH 3100 C was ordered for solid detection inwater, the tuning fork is set to the density of water. In air or ifimmersed in water (density: 1 g/cm³ / 0.036 lbs/in), OPTI-SWITCH 3100 C signals uncovered. Only if the vibratingelement is also covered with solids (e.g. sand, sludge, graveletc.) will the sensor signal covered.Fault monitoringThe electronics of OPTISWITCH 3100 C continuously monitorsthe following criteria:l Correct vibrating frequencyl Line break to the piezo driveIf one of these faults is detected, the electronics signals it via adefined current to the signal conditioning instrument. Theconnection cable to the vibrating element is also monitored.Physical principlePower supplyThe tuning fork is piezoelectrically energised and vibrates at itsmechanical resonance frequency of approx. 150 Hz. When thetuning fork is submerged in the product, the vibratingamplitude changes. This change is detected by the integratedoscillator and converted into a switching command.OPTISWITCH 3100 C with NAMUR electronics can beconnected to different NAMUR amplifiers depending to yourrequirements. The specifications for NAMUR amplifiers areavailable in the Technical data.The exact range of the power supply is stated in the Technicaldata in the Supplement.3.3 AdjustmentWith the factory setting, products with a density of >0.02 g/cm³(>0.0008 lbs/in³) can be measured. It is possible to adapt theinstrument for products with lower density >0.008 g/cm³(>0.0003 lbs/in³).On the electronics module you will find the following indicatingand adjustment elements:lllsignal lamp for indication of the switching condition (yellow)potentiometer for adaptation to the product densityMode switch to select the switching condition (reversecharacteristics)8 OPTISWITCH 3100 C - with NAMUR output31356-EN-051207

Product descriptionlSimulation key3.4 Storage and transportPackagingStorage and transport temperatureYour instrument was protected by packaging during transport.Its capacity to handle normal loads during transport is assuredby a test acc. to DIN 55439.The packaging of standard instruments consists of environment-friendly,recyclable cardboard. In addition, the sensor isprovided with a protective cover of cardboard. For specialversions PE foam or PE foil is also used. Dispose of thepackaging material via specialised recycling companies.l Storage and transport temperature see "Supplement -Technical data - Ambient conditions"l Relative humidity 20 … 85 %31356-EN-051207OPTISWITCH 3100 C - with NAMUR output 9

Mounting4 Mounting4.1 General instructionsSwitching pointMoistureIn general, OPTISWITCH 3100 C can be mounted in anyposition. The instrument must be mounted in such a way thatthe tuning fork is at the height of the requested switching point.Use the recommended cable (see chapter "Connecting topower supply") and tighten the cable gland.You can give your OPTISWITCH 3100 C additional protectionagainst moisture penetration by leading the connection cabledownward in front of the cable entry. Rain and condensationwater can thus drain off. This applies mainly to mountingoutdoors, in areas where moisture is expected (e.g. bycleaning processes) or on cooled or heated vessels.Fig. 2: Measures against moisture penetrationTransportPressure/VacuumDo not hold OPTISWITCH 3100 C on the vibrating element.Especially with flange and tube versions, the sensor can bedamaged by the weight of the instrument.Remove the protective cover just before mounting.The process fitting must be sealed if there is gauge or lowpressure in the vessel. Before use, check if the seal material isresistant against the measured product and the processtemperature.HandlingThe vibrating level switch is a measuring instrument and mustbe treated accordingly. Bending the vibrating element willdestroy the instrument.10 OPTISWITCH 3100 C - with NAMUR output31356-EN-051207

MountingWarning:The housing must not be used for screwing in! Tightening cancause damages on the locking piston of the housing.To screw in, use the hexagon above the thread.4.2 Mounting informationSocketFilling openingHorizontal installationThe vibrating element should protrude into the vessel to avoidbuildup. For that reason, avoid using mounting bosses forflanges and screwed fittings. This applies particularly to usewith adhesive products.Install the instrument in such a way that the tuning fork doesnot protrude directly into the filling stream. Should such aninstallation location be necessary, mount a suitable baffleabove or in front of the tuning fork.If such an installation location should be necessary, mount asuitable protective sheet above or in front of the vibratingelement - see illustration a.).In abrasive solids, mounting acc. to illustration b. has proven. Aspout forms in the concave protective sheet preventing wear ofthe protective sheet.To achieve a very precise switching point, you can installOPTISWITCH 3100 C horizontally. However, if the switchingpoint can have a tolerance of a few centimeters, werecommend mounting OPTISWITCH 3100 C approx. 20°inclined to the vessel bottom to avoid buildup.31356-EN-051207OPTISWITCH 3100 C - with NAMUR output 11

Mountinga. b.20°Fig. 3: Horizontal installationa Protective sheetb Concave protective sheet for abrasive solidsInflowing materialFlowIf OPTISWITCH 3100 C is mounted in the filling stream,unwanted switching signals may be generated. Mount OPTI-SWITCH 3100 C at a location in the vessel where no disturbinginfluence from e.g. filling openings, agitators, etc. can occur.If there is movement within the product, the tuning fork ofOPTISWITCH 3100 C should be mounted in such a way thatthe surfaces of the fork are parallel to the product movement.12Fig. 4: Orientation of the tuning fork in case of flow1 Marking with screwed version2 Direction of flow12 OPTISWITCH 3100 C - with NAMUR output31356-EN-051207

MountingAdhesive productsIn case of horizontal mounting in adhesive products, thesurfaces of the tuning fork should be vertical in order to reducebuildup on the tuning fork. On the screwed version you will finda marking on the hexagon. With this, you can check theposition of the tuning fork when screwing it in. When thehexagon touches the seal, the thread can be still turned byapprox. half a turn. This is sufficient to reach the recommendedinstallation position.With flange versions, the fork is directed to the flange holes.1Fig. 5: Vertical installation - marking1 Marking on top with screwed versionBaffle protection against fallingrocksIn applications such as grit chambers or settling basins forcoarse sediments, the vibrating element must be protectedagainst damage with a suitable baffle.>15031356-EN-051207Fig. 6: Baffle protection against damagesOPTISWITCH 3100 C - with NAMUR output 13

Connecting to power supply5 Connecting to power supply5.1 Preparing the connectionNote safety instructionsTake note of safetyinstructions for ExapplicationsSelect power supplySelect connection cableAlways observe the following safety instructions:lConnect only in the complete absence of line voltageIn hazardous areas you should take note of the appropriateregulations, conformity and type approval certificates of thesensors and power supply units.Connect the power supply acc. to the following diagrams. Takenote of the general installation regulations. As a rule, connectOPTISWITCH 3100 C to vessel ground (PA), or in case ofplastic vessels, to the next ground potential. On the side of theinstrument housing there is a ground terminal between thecable entries. This connection serves to drain off electrostaticcharges. In Ex applications, the installation regulations forhazardous areas must be given priority.The data for power supply are stated in the Technical data inthe Supplement.OPTISWITCH 3100 C is connected with standard cable withround 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 forOPTISWITCH 3100 C.Select connectioncable for Ex applicationsTake note of the corresponding installation regulations for Exapplications.5.2 Connection procedureWith Ex instruments, the housing cover may only be opened ifthere is no explosive atmosphere present.Proceed as follows:1 Unscrew the housing cover2 Loosen compression nut of the cable entry14 OPTISWITCH 3100 C - with NAMUR output31356-EN-051207

Connecting to power supply3 Remove approx. 10 cm (4 in) of the cable mantle, stripapprox. 1 cm (0.4 in) insulation from the ends of theindividual wires4 Insert the cable into the sensor through the cable entry5 Lift the opening levers of the terminals with a screwdriver(see following illustration)6 Insert the wire ends into the open terminals according tothe wiring plan7 Press down the opening levers of the terminals, you willhear the terminal spring closing8 Check the hold of the wires in the terminals by lightlypulling on them9 Tighten the compression nut of the cable entry, the sealring must completely encircle the cable10 Screw the housing cover back onThe electrical connection is finished.Fig. 7: Connection steps 5 and 65.3 Wiring plans, signal chamber housing31356-EN-051207The following illustrations apply to the non-Ex as well as to theEEx d version.OPTISWITCH 3100 C - with NAMUR output 15

Connecting to power supplyHousing overview44412 3Fig. 8: Material versions, single chamber housing1 Plastic2 Aluminium3 Stainless steel4 Filter element for pressure compensationElectronics and connectioncompartment, single chamberhousing6VB60N1NAMUR IEC 60947-5-62Simulation534Wiring planFig. 9: Electronics and connection compartment, single chamber housing1 Potentiometer for switching point adaptation2 DIL switch for characteristics reversal3 Simulation key4 Ground terminal5 Terminals6 Control lampFor connection to an amplifier acc. to NAMUR (IEC 60947-5-6,EN 50227). For further information see Technical data in theSupplement.Further information you will find in the Technical data in theSupplement, Ex technical data are specified in the attachedsafety instructions manual.16 OPTISWITCH 3100 C - with NAMUR output31356-EN-051207

+1 2+---+Connecting to power supplyFig. 10: Wiring plan, single chamber housingExternal simulation keyIn addition to the test key on the electronics module, you canconnect an external modulator to start the test procedure.Connect the modulator acc. to the following wiring plan.Terminals 3 and 4 are already bridged.For additional information see "Recurring function test".1 2 3 42+ -13Fig. 11: Wiring plan - External simulation key1 NAMUR amplifier2 Bridge3 External simulation key31356-EN-051207OPTISWITCH 3100 C - with NAMUR output 17

Setup6 Setup6.1 GeneralThe numbers in brackets refer to the following illustrations.Function/ConfigurationOn the electronics module you will find the following indicatingand adjustment elements:l Potentiometer for switching point adaptation (1)l DIL switch for mode adjustment - min/max (2)l Simulation key (3)l Signal lamp (6)6.2 Adjustment elements16VB60NNAMUR IEC 60947-5-62Simulation534Switching point adaptation (1)Fig. 12: Oscillator VB 60N - NAMUR output1 Potentiometer for switching point adaptation2 DIL switch for characteristics reversal3 Simulation key4 Ground terminal5 Terminals6 Control lampYou can adapt the switching point to the solid with thepotentiometer. The switching point is preset and covered by alabel. It must only be modified in special cases.The factory setting of the potentiometer of OPTISWITCH 3100C is mid position (>0.02 g/cm³ or >0.0008 lbs/in³). In case of18 OPTISWITCH 3100 C - with NAMUR output31356-EN-051207

Setupvery light solids, turn the potentiometer completely to the left(>0.008 g/cm³ or >0.0003 lbs/in³). By doing this, OPTISWITCH3100 C will be more sensitive and light solids can be detectedmore reliably.For instruments detecting solids in water, these values are notapplicable. The potentiometer is preset and must not bechanged.Characteristics reversal (2)Simulation key (3)Signal lamp (6)The characteristics reversal can be carried out with the DILswitch. You can choose between falling characteristics (switchposition max.) and rising characteristics (switch position min.).You can have the requested current outputted.Modesl min. -rising characteristic curve (High current whenimmersed)l max. -falling characteristics (Low current when immersed)The NAMUR output can be switched over to falling or risingcharacteristics (see also Function chart).The simulation key is located in a recess on the upper side ofthe oscillator. Push the simulation key with a suitable object(screwdriver, pen, etc.).When the key is pushed, line break between sensor andprocessing unit is simulated. The signal lamp on the sensorextinguishes. The measuring system must signal failure andtake on safe condition when the key is pushed.Keep in mind that the connected instruments are activatedduring operation. By doing this, you can check the correctfunction of the measuring system.Control lamp (LED) for indication of the switching condition.lllyellow = High current >= 2.2 mAdark = Low current

SetupNote:Select the mode setting on the NAMUR amplifier in such a waythat the switching output takes on safe condition if there is afault signal (I = 2.2 mAFalling characteristicsmax.= 2.2 mARising characteristicsmin.

SetupRecurring function testSimulation key on the electronicsmoduleThe recurring function test acc. to IEC 61508 can be carriedout by pushing the simulation key on the electronics module orby briefly (> 2 seconds) interrupting the cable to the sensor.The correct sequence of the switching conditions must bemonitored on the switch amplifier as well as on the connectedsystems. Neither must the sensor be removed nor a responsetriggered by filling the vessel. This applies to OPTISWITCH3100 C with NAMUR oscillator VB E60N.You can carry out the function test with the outputted currentvalues also directly with a safety PLC or a process controlsystem.In applications in conjunction with the NAMUR electronicsmodule VB E60N, a function test can be carried out. Hence theintegration time must be set to 0.5 s. OPTISWITCH 3100 Chas an integrated simulation key. The simulation key islowered on the electronics module. Push the simulation key for> 2 seconds.If OPTISWITCH 3100 C is connected to an SPLC, you have tointerrupt the connection cable to the sensor for > 2 seconds.After releasing the simulation key or briefly interrupting theconnection cable to the sensor, you can check the completemeasuring system on correct function. A switching procedureis simulated during the test.I/mA2,21123 4,5 t/sFig. 13: Flow chart of the function test1 Full signal2 Empty signal31356-EN-051207Check if the switching conditions occur in the correctsequence and the stated time period. If this is not the case,there is a fault in the measuring system. Keep in mind thatOPTISWITCH 3100 C - with NAMUR output 21

Setupconnected instruments are activated during the function test.By doing this, you can check the correct function of themeasuring system.Test procedure(after releasing the simulation key)Sensor currentLevel relayamplifier -overfill protectionLevel relayamplifier -dry runprotectionSignal lampamplifier -overfill protectionSignal lampamplifier -dry runprotectionSignallamp -sensor1. Low Current(approx. 3 s)approx. 1mAenergizedcurrentless2. High Current(approx. 1.5 s)approx. 2.2mAcurrentlessenergized3. Return to the actual operatingconditionNote:Mode B (dry run protection) is not permitted, when used inmeas. chains acc. to IEC 61508.With the stated current values you can carry out the functiontest directly via a safety PLC or a process control system.22 OPTISWITCH 3100 C - with NAMUR output31356-EN-051207

Maintenance and fault rectification7 Maintenance and fault rectification7.1 ServiceWhen used as directed in normal operation, OPTISWITCH3100 C is completely maintenance-free.31356-EN-051207Fault rectification7.2 Fault rectificationOPTISWITCH 3100 C offers maximum reliability. Neverthelessfaults can occur during operation. These may be caused by thefollowing, e.g.:l Sensorl Processl Power supplyl Signal processing.The first measure to be taken is to check the output signal. Inmany cases, the causes can be determined and faultsrectified.? OPTISWITCH 3100 C signals "covered" when the vibratingelement is not submerged (overfill protection)? OPTISWITCH 3100 C signals "uncovered" when thevibrating element is submerged (dry run protection)lSupply voltage too lowà Check the power supplylElectronics defectiveà Push the characteristics reversal switch. If the instrumentthen changes the mode, the instrument may bemechanically damaged. Should the switching functionin the correct mode still be faulty, return the instrumentfor repair.à Push the characteristics reversal switch. If the instrumentthen does not change the mode, the oscillatormay be defective. Exchange the oscillator.à Check if there is buildup on the vibrating element, and ifso, remove it.lUnfavourable installation locationà Mount the instrument at a location where no deadzones or mounds can form in the vessel.OPTISWITCH 3100 C - with NAMUR output 23

Maintenance and fault rectificationà Check if the vibrating element is covered by buildup onthe socket.lWrong characteristics selectedà Set the correct characteristics on the characteristicsreversal switch (overfill protection; dry run protection).Wiring should be carried out acc. to the quiescentcurrent principle.? Signal lamp flashes yellowl Failure on the electronicsà Exchanging the electronics? Signal lamp flashes yellowl instrument defectiveà Exchange instrument or return it for repair7.3 Exchanging the electronicsIn general, all oscillators of series VB60 can be interchanged. Ifyou want to use an oscillator with a different signal output, youcan download the corresponding operating instructions manualfrom our homepage under Downloads.With EExd instruments, the housing cover must only beopened if there is no explosive atmosphere present.Proceed as follows:1 Switch off power supply2 Unscrew the housing cover3 Lift the opening levers of the terminals with a screwdriver4 Pull the connection cables out of the terminals5 Loosen the two screws with a Phillips screwdriver (size 1)24 OPTISWITCH 3100 C - with NAMUR output31356-EN-051207

Maintenance and fault rectification12Fig. 14: Loosen the screws1 Electronics module2 Screws (2 pcs.)6 Remove the old oscillator7 Compare the new oscillator with the old one. The type labelof the oscillator must correspond to that of the oldoscillator. This applies particularly to instruments used inhazardous areas.8 Compare the settings of the two oscillators. Set theadjustment elements of the new oscillator to the settings ofthe old oscillator.Information:Make sure that the housing is not rotated during the electronicsexchange. Otherwise the plug may be in a different positionlater.31356-EN-0512079 Insert the oscillator carefully. Make sure that the plug is inthe correct position.10 Screw in and tighten the two screws with a Phillipsscrewdriver.11 Insert the wire ends into the open terminals according tothe wiring plan12 Close the opening levers of the terminals, you will hear theterminal spring closing13 Check the hold of the wires in the terminals by lightlypulling on them14 Check the tightness of the cable entry. The seal ring mustcompletely encircle the cable.15 Screw the housing cover back onOPTISWITCH 3100 C - with NAMUR output 25

Maintenance and fault rectificationThe electronics exchange is finished.7.4 Instrument repairIf a repair is necessary, please proceed as follows:You can download a return form from our Internet homepagehttp://www.krohne-mar.com/fileadmin/media-lounge/PDF-Download/Specimen_e.pdf.By doing this you help us carry out the repair quickly andwithout having to call back for needed information.lllPrint and fill out one form per instrumentClean the instrument and pack it damage-proofAttach the completed form and possibly also a safety datasheet to the instrument26 OPTISWITCH 3100 C - with NAMUR output31356-EN-051207

Dismounting8 Dismounting8.1 Dismounting stepsWarning:Before dismounting, be aware of dangerous process conditionssuch as e.g. pressure in the vessel, high temperatures,corrosive or toxic products etc.Take note of chapters "Mounting" and "Connecting to powersupply" and carry out the listed steps in reverse order.With Ex instruments, the housing cover may only be opened ifthere is no explosive atmosphere present.8.2 DisposalOPTISWITCH 3100 C consists of materials which canrecycled by specialised recycling companies. We havepurposely designed the electronic modules to be easilyseparable.WEEE directive 2002/96/EGThis 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 specialisedrecycling company or use the municipal collecting points. Theymay only be used for privately used products acc. to theWEEE directive.Correct disposal avoids negative effects to persons andenvironment and ensures recycling of useful raw materials.Materials: see "Technical data"If you cannot dispose of the instrument properly, pleasecontact us about disposal methods or return.31356-EN-051207OPTISWITCH 3100 C - with NAMUR output 27

Functional safety9 Functional safety9.1 GeneralValidityArea of applicationSafety functionRelevant standardsSafety requirementsThis safety manual applies to measuring systems consisting ofOPTISWITCH 3100 C vibrating level switches and integratedoscillator VB60N. The instrument corresponds to a subsystemof type B.The sensor software must correspond at least to version 1.00or higher.The measuring system can be used for level detection ofpowders and granules which meet the specific requirements ofthe safety technology, e.g.:l Mode "max" for overfill protectionl Mode "min" for dry run protectionThe measuring system is qualified in both modes to meet thefollowing requirement degree acc. to IEC 61508-2:l SIL2 with architecture 1oo1D (single channel)l SIL3 with architecture 1oo2D (double-channel/redundant)With a special factory setting, the measuring system is alsosuitable for detection of solids in water (see operatinginstructions manual).The safety function of this measuring system is the detectionand signalling of the condition of the vibration element. Thesafe condition depends on the mode:llIn mode "max": condition "covered"In mode "min": condition "uncovered"l IEC 61508-1, -2, -4- Functional safety of electrical/electronic/programmableelectronic systemsThe failure limit values for a safety function, depending on theSIL class (of IEC 61508-1, 7.6.2)Safety integrity level Low demand mode High demand modeSIL PFD avg PFH4 >=10 -5 up to =10 -9 up to =10 -4 up to =10 -8 up to =10 -3 up to =10 -7 up to =10 -2 up to =10 -6 up to

Functional safetySafety integrity of the hardware for safety-relating subsystemsof type B (IEC 61508-2, 7.4.3)Safe failure fractionHardwarefault toleranceSFF HFT = 0 HFT = 1 HFT = 2

Functional safetyLow demand modeHigh demand modeSafe conditionl The communication via the IIC bus interface is only usedfor default scaling and for service purposes.l The repair time (exchange of the measuring system) after afail-safe error is eight hours (MTTR = 8 h)l In the mode with the lowest demand rate, the reaction timeof a connected control and processing unit to dangerousdetectable errors is max. 1 hour.If the demand rate is only once a year, then the measuringsystem can be used as safety-relevant subsystem in "lowdemand mode" (IEC 61508-4, 3.5.12).If the ratio of the internal diagnostics test rate of the measuringsystem to the demand rate exceeds the value 100, themeasuring system can be treated in the way it is executing asafety function in the mode with low demand rate (IEC 61508-2, characteristics is the value PFD avg (averageProbability of dangerous Failure on Demand). It is dependenton the test interval T Proof between the function tests of theprotective function.For number values see paragraph "Safety-technical characteristics".If the "low demand rate" does not apply, the measuring systemas safety-relevant part system in "high demand mode" shouldbe used (IEC 61508-4, 3.5.12).The fault tolerance time of the complete system must be higherthan the sum of the reaction times or the diagnostics testperiods of all components in the safety chain.Corresponding characteristics is the value PFH (failure rate).For number values see paragraph "Safety-technical characteristics".The safe condition depends on the mode and is stated in thefollowing chart:The characteristics min/max must be set acc. to the mode (seeFunction chart).Overfill protectionDry run protectionSafe condition "covered" "uncovered"Output current in safecondition0.4 … 1 mA 0.4 … 1 mA30 OPTISWITCH 3100 C - with NAMUR output31356-EN-051207

Functional safetyOverfill protectionDry run protectionInterference current "FailLow"Interference current "FailHigh"< 1 mA < 1 mA> 6.5 mA > 6.5 mAFault descriptionConfiguration of the processingunitA safe failure exists if the measuring system goes to thedefined safe condition without being required by the process orthe interference current outputs "Fail low" or "Fail high".If the internal diagnostics system detects an error, aninterference current of < 1 mA will be outputted.A dangerous undetected failure exists if the measuring systemswitches neither to the defined safe condition, nor to failuremode when the process requires it.If the measuring system delivers output currents of "fail low" or"fail high", it can be assumed that there is a failure somewhere.The processing unit must therefore interpret such currents asfailure and output a suitable fault signal.If this is not the case, the appropriate shares of the failure ratesmust be assigned to the dangerous failures. Therefore thestated values in chapter "Safety-relevant characteristics" candeteriorate.The processing unit must correspond to the SIL level of themeasuring chain.The adjustment of the mode on the NAMUR amplifier acc. toIEC 60947-5-6 must be selected in such a way that itsswitching condition takes on safe condition if there is an inputcurrent < 1.2 mA.9.3 SetupMounting and installationThe prevailing plant conditions influence the safety of themeasuring system. Therefore note the mounting and installationinstructions of the appropriate operating instructionsmanual. Mainly important is the correct setting of the mode(min./max.).31356-EN-051207OPTISWITCH 3100 C - with NAMUR output 31

Functional safety9.4 Reaction during operation and in case offailurellllllThe adjustment elements must not be modified duringoperation.In case of modifications during operation, you have to takenote of the safety functions.Occurring fault signals are described in the appropriateoperating instructions manual.In case of detected failures or fault signals, the entiremeasuring system must be switched out of service and theprocess held in a safe condition by means of othermeasures.An electronics exchange is easily possible and describedin the operating instructions manual.If due to the detected failure, the electronics or thecomplete sensor is interchanged, the manufacturer mustbe informed (incl. a fault description).9.5 Recurring function testThe recurring function test serves to reveal potential dangerouserrors that are otherwise not discernible. The function ofthe measuring system must be checked at adequate intervals.The operator is responsible for choosing the type of test andthe intervals in the stated time frame. The time frame dependson the PFD avg value acc. to the chart and diagram in section"Safety-related characteristics".In high demand rate, no recurring function test is arranged inIEC 61508. A proof of the functional efficiency is seen in themore frequent demand of the measuring system. In doublechannel architectures it is useful to proof the redundancy byrecurring function tests in appropriate intervals.The test must be carried out in a way that verifies the flawlessoperation of the safety functions in conjunction with all systemcomponents.This is ensured by a controlled reaching of the response heightduring filling. If filling up to the response height is not possible,then a response of the measuring system must be triggered bya suitable simulation of the level or the physical effect.The methods and procedures used during the tests must bestated and their suitability must be specified. The tests must bedocumented.32 OPTISWITCH 3100 C - with NAMUR output31356-EN-051207

Functional safetyIf the function test proves negative, the entire measuringsystem must be switched out of service and the process heldin a safe condition by means of other measures.In the double channel architecture 1oo2D this appliesseparately to both channels.Recurring function test whenusing the measuring systemas overfill protectionIf the measuring system is used as overfill protection, the proofof the function is ensured by a simple function test which canbe triggered and monitored manually or by a connected controlsystem.This function test is triggered by interrupting the supply cablefor at least two seconds, then a switch on procedure follows asdescribed in the operating instructions manual.If the test is carried out this way, make sure that the vibratingelement is not covered.If the evaluation is made by a control system, the correctsequence of the current change must be checked anddocumented.9.6 Safety-related characteristicsThe failure rates of the electronics and the vibrating systemwere determined by an FMEDA acc. to IEC 61508. Basis forthe 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 basedon the instructions stated in chapter "Planning".Overfill protectionMode switch is set to "max"λ sd 12 FIT safe detected failure (1 FIT = failure/10 9 h)λ su 160 FIT safe undetected failureλ dd 390 FIT dangerous detected failureλ du 47 FIT dangerous undetected failureSFF > 92 % Safe Failure FractionDC S 7 % Diagnosis coverage DC S = λ sd /(λ sd + λ su )DC D 89 % Diagnosis coverage DC D = λ dd /(λ dd + λ du )31356-EN-051207OPTISWITCH 3100 C - with NAMUR output 33

Functional safetyDry run protectionMode switch is set to "min"λ sd 36 FIT safe detected failureλ su 155 FIT safe undetected failureλ dd 366 FIT dangerous detected failureλ du 52 FIT dangerous undetected failureSFF > 91 % Safe Failure FractionDC S 19 % Diagnosis coverage DC S = λ sd /(λ sd + λ su )DC D 88 % Diagnosis coverage DC D = λ dd /(λ dd + λ du )General dataT Diagnosis Diagnosis test periodMTBF = MTTF + MTTRmax. useful life of the measuring system for the safetyfunction100 sec1.56x10 6 happrox. 10 yearsArchitecture 1oo1D - OverfillprotectionSingle channel architectureSIL2 (Safety Integrity Level)HFT = 0 (Hardware Fault Tolerance)Mode switch is set to "max"PFD avgT Proof = 1 yearT Proof = 5 yearsT Proof = 10 years< 0.020 x 10 -2< 0.100 x 10 -2< 0.200 x 10 -2PFH [1/h] < 0.047 x 10 -6 /hArchitecture 1oo1D - Dry runprotectionSIL2 (Safety Integrity Level)HFT = 0 (Hardware Fault Tolerance)Mode switch is set to "min"PFD avgT Proof = 1 yearT Proof = 5 yearsT Proof = 10 years< 0.023 x 10 -2< 0.114 x 10 -2< 0.228 x 10 -2PFH [1/h] < 0.052 x 10 -6 /h34 OPTISWITCH 3100 C - with NAMUR output31356-EN-051207

Functional safetyTime-dependent process ofPFD avgThe time-dependent process of PFD avg reacts in the timeperiod up to 10 years virtually linear to the operating time. Theabove values only apply to the T Proof interval, after which arecurring function test must be carried out.4PFD avg3211 5 10 T ProofFig. 15: Time-dependent process of PFD avg1)1 PFD avg = 02 PFD avg after 1 year3 PFD avg after 5 years4 PFD avg after 10 yearsArchitecture 1oo2Multiple channel architectureSIL3 (Safety Integrity Level)HFT = 1 (Hardware Fault Tolerance)SILSIL3HFT 1If the measuring instrument is used in double channelarchitecture, the safety-relevant characteristics of the selectedstructure of the measuring chain must be calculated specificallyfor the selected application acc. to the above failure rates. ACommon Cause Factor must be taken into account.The measuring system can be used in a diversitary redundantas well as a homogeneous redundant structure.31356-EN-0512071)Numbers see in the above charts.OPTISWITCH 3100 C - with NAMUR output 35

Supplement10 Supplement10.1 Technical dataGeneral dataMaterial 316L corresponds to 1.4404 or 1.4435Materials, wetted parts- Process fitting - Thread 316L- Process fitting - Flange 316L- Process seal Klingersil C-4400- Tuning fork 316L- Extension tube ø 43 mm (ø 1.7 in) 316LMaterials, non-wetted parts- Housing plastic PBT (Polyester), Alu-die casting powder-coated,stainless steel 316L- Seal ring between housing andhousing cover- Ground terminal 316LWeights- with plastic housing 1500 g (53 oz)- with Aluminium housing 1950 g (69 oz)- with stainless steel housing 2300 g (81 oz)Max. lateral loadNBR (stainless steel housing), silicone (Alu/plastic housing)600 N (135 lbf) longitudinal to the fork sideOutput variableOutputtwo-wire NAMUR outputCurrent consumption- Falling characteristics (max.) >=2.2 mA uncovered/

SupplementAmbient conditionsAmbient temperature on the housingStorage and transport temperature-40 … +80°C (-40 … +176°F)-40 … +80°C (-40 … +176°F)Process conditionsParameterProcess pressurelevel of solids-1 … 16 bar (-100 … 1600 kPa /-14.5 … 232 psi)216 bar(232psi)6 bar(87psi)1-50˚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. 16: Process pressure - Product temperature1 Product temperature2 Process pressureOPTISWITCH 3100 C of 316LProcess temperature (thread or flangetemperature) with temperature adapter(option)-50 … +150°C (-58 … +302°F)-50 … +250°C (-58 … +482°F)280˚C(176˚F)340˚C(104˚F)0˚C(32˚F)-50˚C(-58˚F)-40˚C(-40˚F)50˚C(122˚F)100˚C(212˚F)150˚C(302˚F)200˚C(392˚F)1250˚C(482˚F)31356-EN-051207Fig. 17: Ambient temperature - Product temperature1 Product temperature2 Ambient temperature3 Temperature range with temperature adapterDensityOPTISWITCH 3100 C - with NAMUR output 37

Supplement- Standard >0.02 g/cm³ (>0.0007 lbs/in³)- adjustable >0.008 g/cm³ (>0.0003 lbs/in³)Electromechanical dataCable entry/plug 2)- Single chamber housing l 1x cable entry M20x1.5 (cable-ø 5 … 9 mm),1x blind stopper M20x1.5or:l 1x closing cap ½ NPT, 1x blind stopper½ NPTor:Spring-loaded terminalsl1x plug (depending on the version), 1x blindstopper M20x1.5for wire cross section up to 1.5 mm² (0.0023 in²)Adjustment elementsMode switch- Min. rising characteristics (High current when immersed)- Max. falling characteristics (Low current when immersed)Potentiometer for switching point adaptationSimulation key0.02 … 0.1 g/cm³ (0.0007 … 0.036 lbs/in³)simulation of a line break between sensor andprocessing unitVoltage supplySupply voltage (standard characteristics)Open-circuit voltageShort-circuit currentfor connection to an amplifier acc. to NAMURIEC 60947-5-6, approx. 8.2 VU 0 approx. 8.2 VI U approx. 8.2 mAElectrical protective measuresProtection IP 66/IP 67Overvoltage categoryIIIProtection classII2)Depending on the version M12x1, acc. to DIN 43650, Harting, Amphenol-Tuchel, 7/8" FF38 OPTISWITCH 3100 C - with NAMUR output31356-EN-051207

SupplementApprovals 3)ATEX II 1G, 1/2G, 2G EExiaIIC T6 + ATEX II 1/2 DIP66 TATEX II 1/2G, 2G EExdIIC T6ATEX II 1/2 DIP66 T 4) 3)Deviating data with Ex applications: see separate safety instructions.31356-EN-0512074)See temperature statements in the safety instructions manualOPTISWITCH 3100 C - with NAMUR output 39

Supplement10.2 DimensionsOPTISWITCH 3100 C 5)~ 69mm(2 23/ 32") ø 77mm(3 1/ 32")~ 69mm(2 23/ 32")ø 77mm(3 1/ 32")~ 116mm(4 9/ 16")ø 84mm(3 5/ 16")112mm(4 13/32")117mm(4 39/64")114mm(4 31/64")½M20x1,5/½ NPTM20x1,5/½ NPTM20x1,51 2 3Fig. 18: Housing versions1 Plastic housing2 Stainless steel housing3 Aluminium housing5)All dimensions in mm (inch).40 OPTISWITCH 3100 C - with NAMUR output31356-EN-051207

Supplement220mm (8 21/32")150mm (5 29/32")22mm(55/64")33mm(1 19/64")G1½Aø 43mm (1 11/ 16 ")Fig. 19: OPTISWITCH 3100 C - Threaded version G1½A31356-EN-051207OPTISWITCH 3100 C - with NAMUR output 41

Supplement178mm (7 1/64")ø 34mm (1 11/ 32 ")Fig. 20: Temperature adapter42 OPTISWITCH 3100 C - with NAMUR output31356-EN-051207

Supplement10.3 CertificatesSIL declaration of conformity31356-EN-051207OPTISWITCH 3100 C - with NAMUR output 43

SupplementFig. 21: SIL declaration of conformity44 OPTISWITCH 3100 C - with NAMUR output31356-EN-051207

SupplementCE declaration of conformity31356-EN-051207Fig. 22: CE declaration of conformityOPTISWITCH 3100 C - with NAMUR output 45

Supplement46 OPTISWITCH 3100 C - with NAMUR output31356-EN-051207

Supplement31356-EN-051207OPTISWITCH 3100 C - with NAMUR output 47

Subject to change without notice31356-EN-051207

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