OPTISWITCH 5100C, 5150C with transistor output - BA
Contents
1. Ada 0 FIT dangerous detected failure Adu 27 FIT dangerous undetected failure SFF gt 89 Yo Safe Failure Fraction Dry run protection Mode switch is set to B Asa 0 FIT safe detected failure 241 FIT safe undetected failure Add 0 FIT dangerous detected failure Aqu 30 FIT dangerous undetected failure SFF gt 89 Yo Safe Failure Fraction General data Theaction Failure reaction time 1 5 sec MTBF MTTF MTTR 3 7x108 h max useful life of the measuring system for the safety approx 10 years function Single channel architecture SIL2 Safety Integrity Level HFT 0 Hardware Fault Tolerance Architecture 1001D Overfill Mode switch is set to A protection PFDavg Trroot 1 year lt 0 012 x 10 Tproor 5 years lt 0 059 x 10 Trroor 10 years lt 0 120 x 10 PFH 1 h lt 0 027 x 108 Architectufe 1001D j Dry run rotection P Mode switch is set to B PFDavg Tproor 1 year lt 0 013 x 102 Tproor 5 years 0 066 x 10 Tproot 10 years lt 0 130 x 10 PFH 1 h lt 0 030 x 109 OPTISWITCH 5100 C 5150 C with transistor output 29 Functional safety Architecture 1002D Overfill protection Architecture 1002D Dry run protection Time dependent process of PFDavg Double channel architecture SIL3 Safety Integrity Level HFT 1 Hardware Fault Tolerance Here you see an example how the measuring s2. HFT 0 60 up to lt 90 90 up to lt 99 2 99 Yo SIL4 9 2 Planning e The measuring system must be operated acc to the quiescent current principle Mode A overfill protection max Mode B dry run protection min e The measuring system must be used acc to the The application specific limits must be maintained and the The fault tolerance time of the complete system must be higher than the reaction time of the measuring system It must be used only in products to which the materials of the vibrating system are sufficiently chemically resistant Solids in the measured product 55 mm 50 2 in application e specifications must not be exceeded e e In min operation also avoid e Buildup on the vibrating system e e Foam generation with a density 50 5 g cm 50 018 Ibs in OPTISWITCH 5100 C 5150 C with transistor output 25 Functional safety Assumptions Low demand mode High demand mode For the implementation of FMEDA Failure Mode Effects and Diagnostics Analysis the following assumptions form the basis e Failure rates are constant wear of the mechanical parts is not taken into account e Failure rates of external power supplies are not included Multiple errors are not taken into account e The average ambient temperature during the operating time is 40 C 104 F e The environmental conditions correspond to an average industrial
3. this operating instructions manual Ex specific safety instructions with Ex versions and if necessary further certificates OPTISWITCH 5100 C 5150 C consists of the following components e Housing cover e Housing with electronics e process fitting with tuning fork Fig 1 OPTISWITCH 5100 C 5150 C with plastic housing 1 Housing cover 2 Housing with electronics S Process fitting 3 2 Principle of operation OPTISWITCH 5100 C 5150 C is a level sensor with tuning fork for level detection It is designed for industrial use in all areas of process technology and is used in liquids Typical applications are overfill and dry run protection With a tuning fork of only 40 mm length OPTISWITCH 5100 C 5150 C can be also mounted e g in pipelines from DN 25 The small tuning fork allows the use in vessels tanks and pipes OPTISWITCH 5100 C 5150 C with transistor output 7 Product description Physical principle Power supply Thanks to its simple and robust measuring system OPTI SWITCH 5100 C 5150 C is virtually unaffected by the chemical and physical properties of the liquid It functions also under difficult conditions such as turbulence air bubbles foam generation buildup strong external vibration or changing products Fault monitoring The electronics module of OPTISWITCH 5100 C 5150 C monitors continuously the following criteria via the frequency evaluation e strong
4. A paid Fig 16 SIL declaration of conformity OPTISWITCH 5100 C 5150 C with transistor output 39 Supplement CE declaration of conformity CE Konformitatserklarung Declaration of conformity D claration de eonformsit KROHNE Kroeber LAB Lat WIR Kama lian welll in plaque eerie Pub zum Prod dedama uezin OPTIBWTTCH 190 C CPTIEWITTCH 8200 C mit Aaa Abh raap Gwipur seer ori minia PDA ra Taano gaang with nasa carpe arao suma asyano VERTI on baba pnl with bore Dual eed porte bre ret HAMUP Auegeeg iwih HAMUR cupri ave sortie ARUP JE dh ACTI api A honres iret i ka tech Bes ect in Gb in Corer enh the aang haaa fugue ma naa cate Hana Lan jd WETDAA Eames Greece Erin EM EA 100 Himm El lriiasion i asscsoribil e eran a ENSE aT AA aad EN tiirlb 1 2261 par ien Bauan dei Fochienn i Esto Fea poems ri Decitre coffee num aaa dam redia TM EO E38 Evan ig aes p yh pal E Jpn Tarim ge Fig 17 CE declaration of conformity 40 OPTISWITCH 5100 C 5150 C with transistor output 229090 NA Z2F0E 30427 EN 050622 Manufacturer declaration Audrey HOZ hier arar den Fa Entes S 45 Lin ri BF Fama Rorara Tees s e Renpaigrentheder Typen OPTHIMTCH 51 C E19 C EXOR C RERO E md AAA in ladrar rit DATH BON a Aba 73 Puede be eee Cen ae der las doe sons a ds cana de third nika Corrs ron werden EE A Tiniem gral Hirn chiesa Isah
5. Ground terminal Terminals QA WM 2 We recommend connecting OPTISWITCH 5100 C 5150 C in such a way that the switching circuit is open when there is a level signal line break or failure safe condition The instrument is used to control relays contactors magnet valves warning lights horns as well as PLC inputs NG A12 1 2 3 4 Fig 9 NPN action 16 OPTISWITCH 5100 C 5150 C with transistor output c90S0 N3 Zcv0O 30427 EN 050622 Connecting to power supply mk Fig 10 PNP action OPTISWITCH 5100 C 5150 C with transistor output 17 Set up Function Configuration 6 Set up 6 1 General The numbers in brackets refer to the following illustrations The switching condition of the electronics can be checked with plastic housing and closed housing cover LED display In the basic adjustment products with a density 50 7 g cm 50 025 Ibs in can be detected In liquids with lower density you must set the switch to 50 5 g cm 50 018 Ibs in On the electronics module you will find the following indicating and adjustment elements e LED display 1 e DIL switch for mode adjustment A B 2 e DIL switch for sensitivity adjustment 3 Note For test purposes immerse the tuning fork of OPTISWITCH 5100 C 5150 C always in liquids Do not test the function of OPTISWITCH 5100
6. 050622 Connecting to power supply Housing overview Remove approx 10 cm 4 in of the cable mantle strip approx 1 cm 0 4 in insulation from the ends of the individual wires Insert the cable into the sensor through the cable entry Open the terminals with a screwdriver Insert the wire ends into the open terminals according to the wiring plan Tighten the terminals with a screwdriver Check the hold of the wires in the terminals by lightly pulling on them Tighten the compression nut of the cable entry the seal ring must completely encircle the cable 10 Screw the housing cover back on The electrical connection is finished 5 3 Wiring plans single chamber housing The following illustrations apply to the non Ex as well as to the EEx d version 0 OUO 9S Fig 7 Material versions single chamber housing AO Plastic not with EEx d Aluminium Stainless steel not with EEx d Filter element for pressure compensation not with EEx d OPTISWITCH 5100 C 5150 C with transistor output 15 Connecting to power supply Electronics and connection compartment Wiring plan Ww E60T UR ue M pc m 400m Tas n Fig 8 Electronics and connection compartment single chamber housing LED display DIL switch for mode adjustment DIL switch for switching point adaptation
7. C 5150 C with the hand This can damage the sensor 6 2 Adjustment elements Fig 11 Oscillator SW E60T Transistor output 1 LED display 2 DIL switch for mode adjustment 3 DIL switch for switching point adaptation 18 OPTISWITCH 5100 C 5150 C with transistor output 229090 NA Z2F0E 30427 EN 050622 Set up LED display 1 Mode adjustment 2 Sensitivity adjustment 3 Diode for indication of the switching condition e green output conducts e red output blocks e red flashing failure With the mode adjustment A B you can change the switching condition of the relay You can set the required mode acc to the Function chart A max detection or overfill 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 cm 0 018 0 025 Ibs in In the basic adjustment liquids with a density of gt 0 7 g cm 0 025 Ibs in can be detected In products with lower density you must set the switch to gt 0 5 g cm 0 018 Ibs in The specifications for the position of the switching point relate the water density value 1 0 g cm 0 036 Ibs in In products with another density the switching point shifts depending on the density and installation in direction of the housing or tuning fork end 6 3 Function chart The following chart provides an overview of the switching conditions
8. Storage and transport tempe rature 50 7 g cm 50 025 Ibs in can be detected The instrument can be adapted if products with lower density should be measured On the electronics module you will find the following indicating and adjustment elements e LED for indication of the switching status green red e DIL switch for switching point adaptation e Mode switch to select 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 atest acc to DIN 55439 The packaging of standard instruments consists of environ ment friendly recyclable cardboard In addition the sensor is provided with a protective cover of ABS For special versions PE foam or PE foil is also used Dispose of the packaging material via specialised recycling companies e Storage and transport temperature see Supplement Technical data Ambient conditions e Relative humidity 20 85 Yo OPTISWITCH 5100 C 5150 C with transistor output 9 Mounting Switching point 4 Mounting 41 General instructions In general OPTISWITCH 5100 C 5150 C can be mounted in any position The instrument must be mounted in any position The instrument must be mounted in such a way that the tuning fork is at the height of the requested switching point The tuning fork has lateral markings notches marking the switching point with vertical
9. The test must be carried out in a way that verifies the flawless operation of the safety functions in conjunction with all system components This is ensured by a controlled reaching of the response height during filling If filling up to the response height is not possible then a response of the measuring system must be triggered by a suitable simulation of the level or the physical effect The methods and procedures used during the tests must be stated and their suitability must be specified The tests must be documented If the function test proves negative the entire measuring system must be switched out of service and the process held in a safe condition by means of other measures In the double channel architecture 1002D this applies separately to both channels 9 6 Safety related characteristics The failure rates of the electronics and the vibrating systems are determined by an FMEDA acc to IEC 61508 These calculations are based on component failure rates acc to SN 29500 All numerical values refer to an average ambient temperature during the operating time of 40 C 104 F The calculations are also based on the specifications stated in chapter Planning 28 OPTISWITCH 5100 C 5150 C with transistor output 229090 NA Z2F0E 30427 EN 050622 Functional safety Overfill protection Mode switch is set to A Asa 0 FIT safe detected failure 1 FIT failure 10 h 243 FIT safe undetected failure
10. corrosion or damage of the tuning fork e no vibration e line break to the piezo drive If a fault is detected or in case the power supply fails the electronics takes on a defined switching condition i e the output transistor blocks safe condition OPTISWITCH 5100 C 5150 C fulfills the requirements of IEC 61508 and 61511 of SIL2 see Supplement 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 subjected to temperature shock limitations The frequency changes if the tuning fork is covered by the medium This change is detected by the integrated oscillator and converted into a switching command OPTISWITCH 5100 C 5150 C is a compact instrument i e it can be operated without external evaluation system The integrated electronics evaluates the level signal and outputs a switching signal With this switching signal a connected device can be operated directly e g a warning system a PLC a pump etc The exact range of the power supply is stated in the Technical data in the Supplement 3 3 Adjustment The switching condition of OPTISWITCH 5100 C 5150 C with plastic housing can be checked when the housing is closed LED display In the basic adjustment products with a density OPTISWITCH 5100 C 5150 C with transistor output 229090 NA Z2F0E 30427 EN 050622 Product description Packaging
11. environment e The lifetime of the components is around 8 to 12 years IEC 61508 2 7 4 7 4 remark 3 e The processing unit evaluates the output circuit of the measuring system acc to the quiescent current principle e The repair time exchange of the meas system after a fail safe error is eight hours MTTR 8 h e Inthe mode with the lowest demand rate the reaction time of a connected control and processing unit to dangerous detectable errors is max 1 hour If the demand rate is only once a year then the measuring system can be used as safety relevant subsystem in low demand mode IEC 61508 4 3 5 12 If the ratio of the internal diagnostics test rate of the measuring system to the demand rate exceeds the value 100 the measuring system can be treated in the way it is executing a safety function in the mode with low demand rate IEC 61508 2 7 4 3 2 5 Corresponding characteristics is the value PFD average Probability of dangerous Failure on Demand It is dependent on the test interval Tproot between the function tests of the protective function Numbers see paragraph Safety technical characteristics If the low demand mode does not apply the measuring system must be used as safety relevant subsystem in high demand IEC 61508 4 3 5 12 The fault tolerance time of the complete system must be higher than the sum of the reaction times or the diagnostics test periods of all components in the safety chain
12. fork position after being screwed in Remove therefore the supplied seal from the thread of OPTISWITCH 5100C 5150C 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 instrument versions e g enamel Screw OPTISWITCH 5100 C 5150 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 5100 C 5150 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 aligned with the direction of flow 12 OPTISWITCH 5100 C 5150 C with transistor output 229090 NA Z2F0E 30427 EN 050622 Mounting Adhesive products Inflowing medium Flow Enamel coating Fig 6 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 be still turned by approx half a turn This is sufficient to reach the recommended installation position With flange versions the fork
13. is directed to the flange holes In case of adhesive and viscous products the tuning fork should protrude into the vessel to avoid buildup Therefore sockets for flanges and mounting bosses should be avoided with horizontal mounting If OPTISWITCH 5100 C 5150 C is mounted in the filling stream unwanted switching signals can be generated Mount OPTISWITCH 5100 C 5150 C at a location in the vessel where no disturbing influence from e g filling openings agitators etc can occur If there is movement within the product the tuning fork of OPTISWITCH 5100 C 5150 C should be mounted in such a way that the surfaces of the fork are parallel to the product movement Instruments with enamel coating should be treated very carefully and shocks should be avoided Unpack OPTI SWITCH 5100 C 5150 C directly before installation Insert OPTISWITCH 5100 C 5150 C carefully into the vessel opening and avoid touching any sharp vessel parts OPTISWITCH 5100 C 5150 C with transistor output 13 Connecting to power supply Note safety instructions Take note of safety instructions for Ex applications Select power supply Select connection cable Select connection cable for Ex applica tions 5 Connecting to power supply 5 1 Preparing the connection Always observe the following safety instructions e Connect only in the complete absence of line voltage In hazardous areas you should take note of the a
14. the instrument then does not change the mode the oscillator may be defective Exchange the oscillator Unfavourable installation location Mount the instrument at a location where no dead zones or air bubbles can form in the vessel Wrong mode selected gt Set the correct mode on the mode switch max overfill protection min dry run protection Wiring should be carried out acc to the quiescent current principle LED flashes red Electronics has detected a failure gt exchange instrument or return it for repair OPTISWITCH 5100 C 5150 C with transistor output 21 Maintenance and fault rectification LED flashes alternately red and green instrument defective gt exchange instrument or return it for repair 7 3 Instrument repair If a repair is necessary please proceed as follows You can download a return form from our Internet homepage http Avww krohne mar com fileadmin media lounge PDF Download Specimen_e pdf By doing this you help us carry out the repair quickly and without having to call back for needed information e Print and fill out one form per instrument e Clean the instrument and pack it damage proof e Attach the completed form and possibly also a safety data sheet to the instrument 22 OPTISWITCH 5100 C 5150 C with transistor output c90S0 N3 ZcvO 30427 EN 050622 Dismounting 8 Dismounting 8 1 Dismounting procedure Warning Before dismount
15. C 0 OVO Y G1A 1 NPT 3 4 NPT GIA T NPT E e e Q OCO Y ela 233 7mm Es 1 21 64 Oj Eo i 2 UNO Ba Fig 15 OPTISWITCH 5100 C 5150 C Threaded version Thread Tri Clamp Cone DN 25 Bolting DN 40 Flange Gas tight leadthrough Temperature adapter NOUA ONS 38 OPTISWITCH 5100 C 5150 C with transistor output c90S0 N3 ZcvO 30427 EN 050622 Supplement 10 3 Certificates SIL declaration of conformity Kanfarmitk taarklilrung declaration of conformity D claration de confarmit IEC 61508 IEC 81511 ERDRE 5A X Lea Cora 26103 ROMAE Franca erre as Harada Sams che Vibert kr di in HH Pap ag pan peke dere en tani ud Fabiiczwr que ee ee a DPTIEWITCH 6100 C E158 C 5200 C 5250 C mit with avec SWESSC R FT NF Ex sha ertaprcreradias Detras Kapit Punkin Shana according o EC 871511 arg kaa lor naay iatrurmanind malamn 557 Tha alat Wein pcd CULTE d cR ee ani a Tat ne ha Ut TUE Mag De COH end heen corrinpornrdorgy vera minsan chepher Parokoral Kukay Dons snnt b a RON De M RATA Db BANG TY HUKAY GAT C 81801 Lax carach rnbzuam tach aa maba in mico cei que las comigsas de ah portes dana la Safety bari aont d reapecier Decir im solos inchriqua da mite gn aras mi chapirg Su kscacosadia Pera 06 200 RRE BAR NG cs NA y Di Paran Elen Cachi Boe Depor
16. Corresponding characteristics is the value PFH failure rate Numbers see paragraph Safety technical characteristics 26 OPTISWITCH 5100 C 5150 C with transistor output 229090 NA Z2F0E 30427 EN 050622 Functional safety Safe condition and fault description Configuration of the proces sing unit Mounting and installation The safe condition of the measuring system is the switched off status quiescent current principle e SWE6OT transistor output Transistor blocks A fail safe failure safe failure exists if the measuring system changes to the defined safe condition without demand of the process A dangerous undetected failure exists if the measuring system does not go to the defined safe condition when required by the process The processing unit must evaluate the output circuit of the measuring system by taking the quiescent current principle into account The processing unit must correspond to the SIL level of the measuring chain 9 3 Setup The prevailing plant conditions influence the safety of the measuring system Therefore note the mounting and installa tion instructions of the appropriate operating instructions manual Mainly important is the correct setting of the mode A B The switching point of the measuring system must be adapted depending on the density limits in the operating instructions manual 9 4 Reaction during operation and in case of failure e The adjustment ele
17. Operating Instructions OPTISWITCH 5100 C 5150 C with transistor output Variable area flowmeters Vortex flowmeters Flow controllers Electromagnetic flowmeters if Ultrasonic flowmeters Mass flowmeters Level measuring instruments Communications engineering Engineering systems amp solutions Switches counters displays and recorders Heat metering Pressure and temperature Contents Contents 1 About this document 1 FUNCION eeren easet ette e kgs 4 12 Target group nsaan aana nanan 4 1 3 Symbolism used naaa a 4 2 For your safety 2 1 Authorised persomnel 5 2 2 Appropriate use llle ess 5 2 3 Warning about misuse 5 2 4 General safety instructions 5 25 CE conformity olco ecc e ees 5 26 SIL conformity o 6 2 7 Safety information for Ex areas 6 3 Product description 3 1 Configuration llle 7 3 2 Principle of operation 7 3 3 Adjusiment 0 0000 ee eee 8 3 4 Storage and transport 9 4 Mounting 4 1 General instructiONS o oo oo oo 10 4 2 Mounting informati0N o o oo 12 5 Connecting to power supply 5 1 Preparing the connection 14 5 2 Connection procedure 14 5 3 Wiring plans single chamber housing 15 6 Set up 61 General 0000 ai e
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19. ard in front of the cable entry Rain and condensation water can thus drain off This applies mainly to mounting outdoors in areas where moisture is expected e g by cleaning processes or on cooled or heated vessels o0 oWo c e Fig 5 Measures against moisture penetration OPTISWITCH 5100 C 5150 C with transistor output 11 Mounting Transport Pressure Vacuum Handling Welding the socket Do not hold OPTISWITCH 5100 C 5150 C on the tuning fork Particularly with flange or tube versions the tuning fork can be damaged by the instrument weight Transport enamelled and ECTFE coated instruments very carefully and avoid touching the tuning fork Remove the protective cover just before mounting The process fitting must be sealed if there is gauge or low pressure in the vessel Before use check if the seal material is resistant against the measured product and the process temperature The vibrating level switch is a measuring instrument and must be treated accordingly Bending the vibrating element will destroy the instrument Warning The housing must not be used to screw the instrument in Applying tightening force to the housing can damage its internal mechanical components To screw in use the hexagon above the thread 4 2 Mounting information OPTISWITCH 5100 C 5150 C has a defined thread starting point This means that every OPTISWITCH 5100 C 5150 C is in the same
20. depending on the adjusted mode and level Control lamp ModE A transistor conducts Overfill protection vr X green Mode A transistor blocks Overfill protection N yt WU red Moda B transistor conducts Dry run protection Y Y pos CI 1 green OPTISWITCH 5100 C 5150 C with transistor output 19 Set up Level Switching status Control lamp Mode B transistor blocks Dry run protection x red Failure of the sup any transistor blocks ply voltage mode A B O Failure transistor blocks flashes red 20 OPTISWITCH 5100 C 5150 C with transistor output c90S0 N3 ZcvO 30427 EN 050622 Maintenance and fault rectification 7 Maintenance and fault rectification 74 Maintenance When used as directed in normal operation OPTISWITCH 5100 C 5150 C is completely maintenance free 7 2 Fault rectification Checking the switching signal OPTISWITCH 5100 C 5150 C signals covered when the vibrating element is not submerged overfill protection OPTISWITCH 5100 C 5150 C signals uncovered when the vibrating element is submerged dry run protection Supply voltage too low gt Check the power supply Electronics defective Push the mode switch If the instrument then changes the mode the instrument may be mechanically damaged Should the switching function in the correct mode still be faulty return the instrument for repair Push the mode switch If
21. ee 18 6 2 Adjustment elements 18 6 3 Function chart llle eee 19 7 Maintenance and fault rectification 7 4 Maintenance l l eee 21 7 2 Faultrectification 21 7 3 Instrument repair a 22 8 Dismounting 8 1 Dismounting procedure 23 82 Disposal cee eee ee eee 23 2 OPTISWITCH 5100 C 5150 C with transistor output 229090 NA Z2F0E 30427 EN 050622 Contents 9 Functional safety 9 1 Generali see el I e p ir 24 92 Planning 25 9 3 Setup cerise a di aa 27 9 4 Reaction during operation and in case of failure 27 9 5 Recurring function test 28 9 6 Safety related characteristics 28 10 Supplement 10 1 Technical data o o o 32 10 2 Dimensions 0 0000 ce eee eee 37 10 3 Certificates e dre rin ea ees 39 OPTISWITCH 5100 C 5150 C with transistor output 3 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 of OPTISWITCH 5100 C 5150 C 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 inf
22. ements Mode switch A max detection or overfill protection B min detection or dry run protection Density switch 0 5 0 5 2 5 g cm 0 018 0 9 oz in 0 7 0 7 2 5 g cm 0 025 0 9 oz in Power supply Power supply 10 55 V DC Power consumption max 0 5 W Electrical protective measures Protection IP 66 IP 67 Overvoltage category Il Protection class II 2 Depending on the version M12x1 acc to DIN 43650 Harting Amphenol Tuchel 7 8 FF OPTISWITCH 5100 C 5150 C with transistor output 35 Supplement Approvals WHG Ship approvals ATEX II 1 2G 2G EEx d IIC T69 Overfill protection acc to WHG Ship approvals 3 4 Deviating data with Ex applications see separate safety instructions only with Aluminium housing 36 OPTISWITCH 5100 C 5150 C with transistor output 229090 NA Z2F0E 30427 EN 050622 Supplement 10 2 Dimensions Housing 69mm 2 23 32 9 77mm 3 1 2 0 OWNOo S M20x1 5 Ye NPT 112mm 4 13 32 M20x1 5 Ye NPT 69mm 2 23 32 877mm 3 1 32 0 OVO o 4 99 64 116mm 4 9 16 84mm 3 5 16 0 OYO 9S 4 31 64 M20x1 5 Ye NPT Fig 14 Housing versions 1 Plastic housing 2 Stainless steel housing S Aluminium housing OPTISWITCH 5100 C 5150 C with transistor output 37 Supplement OPTISWITCH 5100 C 5150
23. ing be aware of dangerous process condi tions 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 be opened only if no explosive atmosphere is present 8 2 Disposal OPTISWITCH 5100 C 5150 C consists of materials which can be recycled by specialised recycling companies We have purposely designed the electronic modules to be easily separable Mark the instrument as scrap and dispose of it according to government regulations electronic scrap ordi nance Materials see Technical data If you cannot dispose of the instrument properly please contact us about disposal methods or return OPTISWITCH 5100 C 5150 C with transistor output 23 Functional safety Validity Area of application Safety function Relevant standards 9 Functional safety 9 1 General This safety manual applies to measuring systems consisting of OPTISWITCH 5100 C 5150 C vibrating level switches and integrated oscillator SWE60T Note For OPTISWITCH 5100 C 5150 C with enamelled fork oscillator SWE60TEx E or SWEGOTEx E1 is used The measuring system can be used for level detection of liquids which meet the specific requirements of the safety technology e g e Mode for overfill protection e Mode for dry run protection The measuring s
24. ments must not be modified during operation e In case of modifications during operation you have to take note of the safety functions e Occurring fault signals are described in the appropriate operating instructions manual e In case of detected failures or fault signals the entire measuring system must be switched out of service and the process held in a safe condition by means of other measures e Anelectronics exchange is easily possible and described in the operating instructions manual OPTISWITCH 5100 C 5150 C with transistor output 27 Functional safety e lf due to the detected failure the electronics or the complete sensor is interchanged the manufacturer must be informed incl a fault description 9 5 Recurring function test The recurring function test serves to reveal potential danger ous errors that are otherwise not discernible The function of the measuring system must be checked at adequate intervals The operator is responsible for choosing the type of test and the intervals in the stated time frame The time frame depends on the PFD value acc to the chart and diagram in section Safety related characteristics With high demand rate a recurring function test is not requested in IEC 61508 The function of the measuring system is proven by the frequent use of the system In double channel architectures it is useful to proof the redundancy by recurring function tests in appropriate intervals
25. mounting The switching point refers to water with the basic setting of the sensitivity switch 5 0 7 g cm gt 0 025 Ibs in When mounting OPTISWITCH 5100 C 5150 C make sure that this marking is at the height of the requested switching point Keep in mind that the switching point of the instrument is shifted if the medium has a density other than water water 1 0 g cm 20 036 Ibs in For products 0 7 g cm 0 025 Ibs in3 and 50 5 g cm 50 018 Ibs in the density switch must be set to gt 0 5 g cm S Ono A Fig 2 Vertical mounting Switching point approx 13 mm ca 0 51 in Switching point with lower density Switching point with higher density Switching point approx 27 mm approx 1 06 in AROMA 10 OPTISWITCH 5100 C 5150 C with transistor output 229090 NA Z2F0E 30427 EN 050622 Moisture Mounting ono A Fig 3 Horizontal mounting 1 Switching point Fig 4 Horizontal mounting recommended installation location particularly for adhesive products 1 Switching point 2 Marking with screwed version on top with flange versions directed to the flange holes Use the recommended cable see chapter Connecting to power supply and tighten the cable entry You can give your OPTISWITCH 5100 C 5150 C additional protection against moisture penetration by leading the con nection cable downw
26. nge OPTISWITCH 5100 C 5150 C of 316L 50 150 C 58 302 F Hastelloy C4 2 4610 Process temperature thread or flange temperature with temperature adapter option OPTISWITCH 5100 C 5150 C of 50 250 C 58 482 F 316L Hastelloy C4 OPTISWITCH 5100 C 5150C 50 200 C 58 392 F enamelled OPTISWITCH 5100 C 5150 C with 50 150 C 58 302 F ECTFE coating OPTISWITCH 5100 C 5150 C with 50 150 C 58 302 F PFA coating C sc 82 50 C 100 C 150 C 200 C 250 C 58 F 122 F 212 F 302 F 892 F 482 F 40 i 40 F Fig 13 Ambient temperature Product temperature 1 Product temperature 2 Ambient temperature 3 Temperature range with temperature adapter Viscosity dynamic 0 1 10 000 mPa s requirement with density 1 Density 0 7 2 5 g cm 0 025 0 09 Ibs in 0 5 2 5 g cm 0 018 0 09 Ibs in by switching over 34 OPTISWITCH 5100 C 5150 C with transistor output c90S0 N3 ZcvO 30427 EN 050622 Supplement Electromechanical data Cable entry plug 2 Single chamber housing e 1xcable entry M20x1 5 cable o 5 9 mm 1x blind stopper M20x1 5 or e 1x closing cap Y NPT 1x blind stopper Ve NPT Of e 1x plug depending on the version 1x blind stopper M20x1 5 Screw terminals for wire cross section up to 1 5 mm 0 0023 in Adjustment el
27. ormation Caution warning danger This symbol informs you of a dangerous situation that could occur Ignoring this cautionary note can impair the person and or the instrument Ex applications This symbol indicates special instructions for Ex applications List The dot set in front indicates a list with no implied sequence Action This arrow indicates a single action Sequence Numbers set in front indicate successive steps in a procedure OPTISWITCH 5100 C 5150 C with transistor output c90S0 N3 ZcvO 30427 EN 050622 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 5100 C 5150 C is a sensor for level detection Detailed information on the application range of OPTISWITCH 5100 C 5150 C is available in chapter Product description 2 3 Warning about misuse Inappropriate or incorrect use of the instrument can give rise to application specific hazards e g vessel overfill or damage to system components through incorrect mounting or adjustment 2 4 General safety instructions OPTISWITCH 5100 C 5150 C is a high tech instrument requiring the strict observance of standard reg
28. parts Process fitting thread Process fitting Flange Process seal Tuning fork Extension tube 21 3 mm 0 84 in Sensor length length OPTISWITCH 5100 C 5150 C Materials non wetted parts Housing Seal ring between housing and housing cover waveguide in the housing cover Ground terminal temperature adapter option gastight leadthrough option Weights Plastic housing Aluminium housing Stainless steel housing Layer thickness enamel ECTFE PFA 316L 2 4602 Hastelloy C4 316L 316L with Hastelloy C4 plated enamel led steel 316L with ECTFE coating 316L with PFA coating Klingersil C 4400 316L 2 4610 Hastelloy C4 316L 2 4610 Hastelloy C4 2 4610 Hastelloy C4 enamelled 316L with ECTFE coating 316L with PFA coating see Supplement Dimensions plastic PBT Polyester Alu die casting pow der coated stainless steel 316L NBR stainless steel housing silicone Alu plastic housing PMMA Makrolon 316L 316L 316L glass 760 g 27 oz 1170 g 41 oz 1530 g 54 oz 0 8 mm 0 03 in 0 5 mm 0 02 in 0 5 mm 0 02 in 32 OPTISWITCH 5100 C 5150 C with transistor output c90S0 N3 Zcv0O 30427 EN 050622 Supplement Surface quality Standard Hygienic version 3A OPTISWITCH 5150 C Process fittings Thread flanges hygienic fittings Coatings ECTFE PFA enamel High vol
29. ppropriate regulations conformity and type approval certificates of the sensors and power supply units Connect the power supply acc to the following diagrams Take note of the general installation regulations As a rule connect OPTISWITCH 5100 C 5150 C to vessel ground PA or in case of plastic vessels to the next ground potential On the side of the instrument housing there is a ground terminal between the cable entries This connection serves to drain off electrostatic charges In Ex applications the installation regulations for hazardous areas must be given priority The data for power supply are stated in the Technical data in the Supplement OPTISWITCH 5100 C 5150 C is connected with standard cable with round wire cross section An outer cable diameter of 5 9 mm 0 2 0 35 in ensures the seal effect of the cable entry If cable with a different diameter or wire cross section is used exchange the seal or use an appropriate cable connection In hazardous areas only use approved cable connections for OPTISWITCH 5100 C 5150 C Take note of the corresponding installation regulations for Ex applications 5 2 Connection procedure With Ex instruments the housing cover may be opened only if no explosive atmosphere is present Proceed as follows 1 Unscrew the housing cover 2 Loosen compression nut of the cable entry 14 OPTISWITCH 5100 C 5150 C with transistor output c90S0 N3 ZcvO 30427 EN
30. tage test enamel gastight leadthrough option leakage rate pressure resistance hygienic fittings Output variable Ra approx 3 um approx 1 18 in Ra 0 8 um 23 15 in G34A 34 NPT G1A 1 NPT DIN from DN 25 ANSI from 1 bolting DN 40 PN 40 Tri Clamp 1 Tri Clamp 172 PN 10 cone DN 25 PN 40 Tuchenhagen Varivent DN 50 PN 10 approx 0 5 0 8 mm approx 0 02 0 03 in approx 0 3 0 5 mm approx 0 01 0 02 in approx 0 8 mm approx 0 03 in max 5 KV 109 mbar l s PN 64 bolting DN 40 PN 40 Tri Clamp 1 Tri Clamp 172 PN 10 cone DN 25 PN 40 Tuchenhagen Varivent DN 50 PN 10 Output Load current Voltage loss Turn on voltage Blocking current Modes adjustable floating transistor output overload and perma nently shortcircuit proof max 400 mA max 1 V max 55 V DC 10 WA A max detection or overfill protection B min detection or dry run protection Accuracy Hysteresis approx 2 mm 0 08 in with vertical installation Integration time approx 500 ms Frequency approx 1200 Hz OPTISWITCH 5100 C 5150 C with transistor output 33 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 Parameter level of liquids Process pressure 1 64 bar 14 5 938 psi depending on the process fitting e g fla
31. ulations and guidelines The user must take note of the safety instructions in this operating instructions manual the country specific instal lation standards e g the VDE regulations in Germany as well as all prevailing safety regulations and accident prevention rules 2 5 CE conformity OPTISWITCH 5100 C 5150 C is in CE conformity with EMC 89 336 EWG fulfils the NAMUR recommendation NE 21 and is in CE conformity with NSR 73 23 EWG Conformity has been judged acc to the following standards e EMC Emission EN 61326 A1 1998 class B Susceptibility EN 61326 1997 A1 1998 e NSR EN 61010 1 1993 OPTISWITCH 5100 C 5150 C with transistor output 5 For your safety 2 6 SIL conformity OPTISWITCH 5100 C 5150 C meets the requirements to the functional safety acc to IEC 61508 IEC 61511 Further information is available 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 Ex approved instruments OPTISWITCH 5100 C 5150 C with transistor output c90S0 N3 ZcvO 30427 EN 050622 Product description Scope of delivery Components Area of application 3 Product description 3 1 Configuration The scope of delivery encompasses e OPTISWITCH 5100 C 5150 C level sensor e Documentation
32. ystem in double channel architecture can be used in an application with demand rate SIL3 A Common Cause Factor of beta 10 worst case is taken into account If the instruments are used in another multiple channel architecture the values must be calculated for the selected application by means of the above failure rates Mode switch is set to A PFDavg Tproor 1 year lt 0 012 x 103 Tproor 5 years lt 0 059 x 10 Tproof 10 years lt 0 120 x 103 PFH 1 h lt 0 027 x 107 Mode switch is set to B PFDavg Tproor 1 year lt 0 013 x 10 Tproof 5 years lt 0 066 x 10 Tproor 10 years lt 0 130 x 103 PFH 1 h lt 0 030 x 10 The time dependent process of PFDayg reacts in the time period up to 10 years virtually linear to the operating time The above values only apply to the Tp oo interval after which a recurring function test must be carried out 30 OPTISWITCH 5100 C 5150 C with transistor output c90S0 N3 ZcvO 30427 EN 050622 Functional safety Proof Fig 12 Time dependent process of PFDavg 1 PFDag 0 2 PFDoyg after 1 year S PFDoyg after 5 years 4 PFDayg after 10 years 1 Numbers see in the above charts OPTISWITCH 5100 C 5150 C with transistor output 31 Supplement 10 Supplement 10 1 Technical data General data Material 316L corresponds to 1 4404 or 1 4435 Materials wetted
33. ystem is qualified in both modes to meet the following requirement degree acc to IEC 61508 2 IEC 61511 e SIL2 with architecture 1001D single channel e SIL3 with architecture 1002D double channel redundant The safety function of this measuring system is the detection and signalling of the condition of the vibration element The safe condition depends on the mode e Overfill protection condition covered e Dry run protection condition uncovered e IEC 61508 1 2 4 Functional safety of electrical electronic programmable electronic systems e IEC 61511 1 Functional safety safety instrumented systems for the process industry sector Part 1 Framework defini tions system hardware and software requirements 24 OPTISWITCH 5100 C 5150 C with transistor output c90S0 N3 ZcvO 30427 EN 050622 Functional safety Safety requirements General instructions and restrictions The failure limit values for a safety function depending on the SIL class of IEC 61508 1 7 6 2 Safety integrity level Low demand mode High demand or continuous mode SIL PFDavg PFH 4 210 up to 10 210 up to 10 3 3107 up to 10 210 up to 107 2 210 up to 10 3107 up to 10 210 up to lt 10 210 up to 10 Safety integrity of the hardware for safety relating subsystems of type A IEC 61508 2 7 4 3 Safe failure fraction Hardware fault tole rance
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