Operating Instructions OPTISWITCH 3100 C with two-wire output
Contents Contents 1 About this document 1.1 1.2 1.3 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. .. .. .. .. .. Configuration. . . . . . . Principle of operation . Adjustment . . . . . . . . Storage and transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8 .. 8 .. 9 . . 10 General instructions . . . . . . . . . . . . . . . . . . . . .
Contents 9 Functional safety 9.1 9.2 9.3 9.4 9.5 9.6 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reaction during operation and in case of failure. Recurring function test . . . . . . . . . . . . . . . . . . . Safety-related characteristics . . . . . . . . . . . . . . 27 28 31 31 31 32 10 Supplement 10.1 Technical data. . . . . . . . . . . . . . .
About this document 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. 1.3 Symbolism used Information, tip, note This symbol indicates helpful additional information.
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 3100 C is a sensor for level detection.
For your safety 2.6 SIL conformity OPTISWITCH 3100 C fulfills the requirements for functional safety acc. to IEC 61508. You will find further information in chapter "Functional safety". 2.7 Safety information for Ex areas Please note the Ex-specific safety information for installation and operation in Ex areas. These safety instructions are part of the operating instructions manual and come with the Exapproved instruments.
Product description 3 Product description 3.
Product description It functions even when exposed to strong external vibration or changing products. Solid detection in water If OPTISWITCH 3100 C was ordered for solids detection in water, the tuning fork is set to the density of water. In air or when immersed in water (density: 1 g/cm³ / 0.036 lbs/in), OPTISWITCH 3100 C signals "uncovered". Only when the vibrating element is also covered with solids (e.g. sand, sludge, gravel etc.) will the sensor signal "covered".
Product description 3.4 Storage and transport Packaging 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 environment-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.
Mounting 4 Mounting 4.1 General instructions Switching point In general, OPTISWITCH 3100 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. Moisture Use the recommended cable (see chapter "Connecting to power supply") and tighten the cable gland.
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 Socket 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.
Mounting a. b. 20° Fig. 3: Horizontal installation a Protective sheet b Concave protective sheet for abrasive solids Inflowing material If OPTISWITCH 3100 C is mounted in the filling stream, unwanted switching signals can be generated. Mount OPTISWITCH 3100 C at a location in the vessel where no disturbing influence from e.g. filling openings, agitators, etc. can occur.
Mounting Adhesive products In case of horizontal mounting in adhesive 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 be still turned by approx. half a turn. This is sufficient to reach the recommended installation position.
Connecting to power supply 5 Connecting to power supply 5.1 Preparing the connection Note safety instructions Always observe the following safety instructions: l Connect only in the complete absence of line voltage Take note of safety instructions for Ex applications In hazardous areas you should take note of the appropriate regulations, conformity and type approval certificates of the sensors and power supply units. Select power supply Connect the power supply acc. to the following diagrams.
Connecting to power supply 3 Remove approx. 10 cm (4 in) of the cable mantle, strip approx. 1 cm (0.
Connecting to power supply Housing overview 4 4 1 Fig. 1 2 3 4 4 2 3 8: 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) Electronics and connection compartment 1 5 2 4 3 Fig.
Connecting to power supply l l red - with submerged vibrating element green - with uncovered vibrating element Take note of the operating instructions manual of the signal conditioning instrument. Suitable signal conditioning instruments are listed under Technical data. 1 29955-EN-060112 Fig.
Setup 6 Setup 6.1 General The numbers in brackets refer to the following illustrations. Function/Configuration On the electronics module you will find the following indicating and adjustment elements: l l l Potentiometer for switching point adaptation (1) DIL switch for mode adjustment - min./max. (2) Signal lamp (5) Note: As a rule, always set the mode with mode switch (2) before starting the setup of OPTISWITCH 3100 C.
Setup 6.2 Adjustment elements 1 5 2 4 3 Fig. 1 2 3 4 5 Switching point adaptation (1) 11: Oscillator VB 60Z - Two-wire output Potentiometer for switching point adaptation DIL switch for mode adjustment Ground terminal Terminals Control lamp With the potentiometer you can adapt the switching point to the solid. It is already factory-preset and must be adjusted only in special cases. By default, the potentiometer of OPTISWITCH 3100 C is set to mid position (>0.02 g/cm³ or >0.0008 lbs/in³).
Setup min. - min.detection or dry run detection) on the signal conditioning instrument. When used on a control system, the following values apply: l min. mode - Vibrating element uncovered - 16 mA ±1 mA - Vibrating element covered - 8 mA ±1 mA l max. mode - vibrating element uncovered - 8 mA ± 1 mA - vibrating element submerged - 16 mA ± 1 mA Control lamp for indication of the switching condition. Signal lamp (5) l l l green = 8 mA red = 16 mA red (flashing) = Failure (<2.3 mA) 6.
Setup Mode on the sensor Level Signal current - Sensor Fault signal (min./max. mode) any Signal lamp sensor <2.3 mA flashes red OPTISWITCH 3100 C level switch with signal conditioning instrument1) The following chart provides an overview of the switching conditions depending on the adjusted mode of the signal conditioning instrument and the level. Note: Keep in mind that the mode switch of OPTISWITCH 3100 C must be always set to "max.".
Maintenance and fault rectification 7 Maintenance and fault rectification 7.1 Maintenance When used as directed in normal operation, OPTISWITCH 3100 C is completely maintenance-free. 7.
Maintenance and fault rectification ? Signal lamp flashes red l Electronics has detected a failure à 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 manual from our homepage under Downloads. With EExd instruments, the housing cover may only be opened if there is no explosive atmosphere present.
Maintenance and fault rectification 7 Compare the new oscillator with the old one. The type label of the oscillator must correspond to that of the old oscillator. This applies particularly to instruments used in hazardous areas. 8 Compare the settings of the two oscillators. Set the adjustment elements of the new oscillator to the settings of the old oscillator. Information: Make sure that the housing is not rotated during the electronics exchange. Otherwise the plug may be in a different position later.
Dismounting 8 Dismounting 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.
Functional safety 9 Functional safety 9.1 General Validity This safety manual applies to measuring systems consisting of OPTISWITCH 3100 C vibrating level switches and integrated oscillator VB60Z. The instrument corresponds to a subsystem of type B. The sensor software must correspond at least to version 1.03 or higher. Area of application The measuring system can be used for level detection of powders and granules which meet the specific requirements of the safety technology, e.g.
Functional safety Safety integrity of the hardware for safety-related subsystems of type B (IEC 61508-2, 7.4.3) Safe failure fraction Hardware fault tolerance SFF HFT = 0 HFT = 1 HFT = 2 <60 % not permitted SIL1 SIL2 60 % up to <90 % SIL1 SIL2 SIL3 90 % up to <99 % SIL2 SIL3 (SIL4) >=99 % SIL3 (SIL4) (SIL4) 9.2 Planning General instructions and restrictions l l l l The measuring system must be used acc.
Functional safety l l l Low demand mode The communication via the IIC bus interface is only used for default scaling and for service purposes. The repair time (exchange of the measuring system) after a fail-safe error is eight hours (MTTR = 8 h) In the mode with the lowest demand rate, the reaction time of a connected control and processing unit to dangerous detectable errors is max. 1 hour.
Functional safety Set the mode switch on the sensor to "max" Use as overfill protection system Safe condition Use as dry run protection system "covered" "uncovered" 12.5 mA … 23.5 mA 2.3 mA … 11.5 mA Error current "Fail Low" < 2.3 mA < 2.3 mA Error current "Fail High" > 23.5 mA > 23.
Functional safety 9.3 Setup Mounting and installation The prevailing plant conditions influence the safety of the measuring system. For this reason, carefully observe the mounting and installation instructions in the operator's manual. It is especially important to make sure the mode setting (min./ max.) is correct. 9.4 Reaction during operation and in case of failure l l l l l l The adjustment elements must not be modified during operation.
Functional safety This is ensured by a controlled reaching of the response height during filling. If filling up to the response height is not possible, then a response of the measuring system must be triggered by a suitable simulation of the level or the physical effect. The methods and procedures used during the tests must be stated and their suitability must be specified. The tests must be documented.
Functional safety Overfill protection Mode switch is set to "max" λsd 49 FIT safe detected failure (1 FIT = failure/109h) λsu 387 FIT safe undetected failure λdd 163 FIT dangerous detected failure λdu 18 FIT dangerous undetected failure Safe Failure Fraction SFF > 97 % DCS 11 % Diagnosis coverage DCS = λsd/(λsd + λsu) DCD 90 % Diagnosis coverage DCD = λdd/(λdd + λdu) Mode switch is set to "min" Dry run protection λsd 39 FIT safe detected failure λsu 373 FIT safe undetected failur
Functional safety DCS 11 % Diagnosis coverage DCS = λsd/(λsd + λsu) DCD 82 % Diagnosis coverage DCD = λdd/(λdd + λdu) General data TDiagnosis Diagnosis test period 100 sec 1.59x106 h MTBF = MTTF + MTTR max. useful life of the measuring system for the safety function Architecture 1oo1D - Overfill protection approx.
Functional safety PFDavg TProof = 1 year TProof = 5 years TProof = 10 years < 0.016 x 10-2 < 0.081 x 10-2 < 0.162 x 10-2 PFH [1/h] < 3.7 x 10-8/h Double channel architecture Here you see an example how the measuring system in double channel architecture can be used in an application with demand rate SIL3. A Common Cause Factor of beta = 10 % (worst case) is taken into account.
Functional safety Time-dependent process of PFDavg PFDavg TProof = 1 year TProof = 5 years TProof = 10 years < 0.016 x 10-3 < 0.079 x 10-3 < 0.160 x 10-3 PFH [1/h] < 2.1 x 10-8/h The time-dependent process of PFDavg reacts in the time period up to 10 years virtually linear to the operating time. The above values only apply to the TProof interval, after which a recurring function test must be carried out. 4 PFDavg 3 2 1 29955-EN-060112 1 5 Fig.
Supplement 10 Supplement 10.1 Technical data General data Material 316L corresponds to 1.4404 or 1.4435 Materials, 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.
Supplement Ambient conditions Ambient temperature on the housing Storage and transport temperature -40 … +80°C (-40 … +176°F) -40 … +80°C (-40 … +176°F) Process conditions Parameter Process pressure level of solids -1 … 16 bar/-100 … 1600 kPa (-14.5 … 232 psi) 2 16 bar (232psi) 6 bar (87psi) -50˚C (-58˚F) 0˚C (32˚F) 1 50˚C (122˚F) 100˚C (212˚F) 150˚C (302˚F) 200˚C (392˚F) 250˚C (482˚F) Fig.
Supplement Density - Standard >0.02 g/cm³ (>0.0007 lbs/in³) - adjustable >0.008 g/cm³ (>0.0003 lbs/in³) Electromechanical data Cable entry/plug3) - Single chamber housing l or: l 1x cable entry M20x1.5 (cable-ø 5 … 9 mm), 1x blind plug M20x1.5 1x closing cap ½ NPT, 1x blind plug ½ NPT or: l Spring-loaded terminals 1x plug (depending on the version), 1x blind plug M20x1.5 for wire cross section up to 1.5 mm² (0.0023 in²) Adjustment elements Mode switch - min. min.
Supplement 29955-EN-060112 ATEX II 1/2 D IP66 T 6) 6) See temperature statements in the safety instructions manual OPTISWITCH 3100 C - with two-wire output 39
Supplement 10.2 Dimensions OPTISWITCH 3100 C7) ~ 69mm (2 23/32") 1 Fig. 1 2 3 2 M20x1,5 3 16: Housing versions Plastic housing Stainless steel housing Aluminium housing All dimensions in mm (inch).
22mm (55/64") 33mm (1 19/64") Supplement G1½A 220mm (8 21/32") 150mm (5 29/32") ø 43mm (1 11/16") 29955-EN-060112 Fig.
178mm (7 1/64") Supplement ø 34mm (1 11/32") Fig.
Supplement 10.3 Certificates 29955-EN-060112 SIL declaration of conformity Fig.
Supplement CE declaration of conformity 44 29955-EN-060112 Fig.
Supplement 29955-EN-060112 Manufacturer declaration Fig.
Supplement 29955-EN-060112 46 OPTISWITCH 3100 C - with two-wire output
29955-EN-060112 Supplement OPTISWITCH 3100 C - with two-wire output 47
Subject to change without notice 29955-EN-060112
