KROHNE OPTIFLEX1100C User Manual

Handbook

OPTIFLEX 1100 C

OPTIFLEX 1100 COPTIFLEX 1100 C

HandbookHandbook

Guided Radar (TDR) Level Meter

Continuous level measurement of liquids and solids

: IMPRINT :::::::::::::::::::::::::::::::::::::::

Subject to change without notice.

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OPTIFLEX 1100 C

CONTENTS

1 Safety instructions 6

1.1 Intended use ..................................................................................................................... 6

1.2 Certification ...................................................................................................................... 6

1.3 Electromagnetic compatibility ......................................................................................... 6

1.4 Safety instructions from the manufacturer ..................................................................... 7

1.4.1 Copyright and data protection ................................................................................................ 7

1.4.2 Disclaimer ............................................................................................................................... 7

1.4.3 Product liability and warranty ................................................................................................ 8

1.4.4 Information concerning the documentation........................................................................... 8

1.4.5 Warnings and symbols used................................................................................................... 9

1.5 Safety instructions for the operator................................................................................. 9

2 Device description 10

2.1 Device description .......................................................................................................... 10

2.2 Nameplates .................................................................................................................... 10

3 Installation 11

3.1 Ø2 mm / 0.08¨ single cable probe (liquid applications)................................................. 11

3.1.1 Scope of delivery ................................................................................................................... 11

3.1.2 Transport............................................................................................................................... 11

3.1.3 How to assemble a single cable probe................................................................................. 12

3.1.4 Mounting position.................................................................................................................. 13

3.1.5 Installation in standpipes (stilling wells and bypass chambers) ......................................... 14

3.1.6 Horizontal cylindrical tanks.................................................................................................. 15

3.2 Coaxial probe (low-viscosity liquid applications)........................................................... 16

3.2.1 Scope of delivery ................................................................................................................... 16

3.2.2 Transport............................................................................................................................... 16

3.2.3 How to assemble the segmented coaxial probe .................................................................. 17

3.2.4 Mounting position.................................................................................................................. 21

3.3 Ø4 mm / 0.15¨ single cable probe (solid applications) .................................................. 22

3.3.1 Scope of delivery ................................................................................................................... 22

3.3.2 Transport............................................................................................................................... 22

3.3.3 How to assemble a single cable probe................................................................................. 23

3.3.4 Mounting position.................................................................................................................. 26

3.4 How to install a device with a threaded connection ...................................................... 27

3.5 Recommendations for pits and tanks made of non-conductive materials ................... 27

3.6 How to turn or remove the signal converter.................................................................. 28

4 Electrical connections 29

4.1 Safety instructions.......................................................................................................... 29

4.2 Electrical installation: 2-wire, loop-powered ................................................................ 29

4.3 Protection category ........................................................................................................31

4.4 How to attach the optional display unit to the device .................................................... 32

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CONTENTS

OPTIFLEX 1100 C

5 Start-up 35

5.1 How to start the device................................................................................................... 35

5.1.1 Start-up checklist ................................................................................................................. 35

5.1.2 How to start the device ......................................................................................................... 35

5.2 Digital display screen (option)........................................................................................ 36

6 Operation 37

6.1 User modes .................................................................................................................... 37

6.2 Normal mode.................................................................................................................. 37

6.3 Configuration mode........................................................................................................ 37

6.3.1 General notes........................................................................................................................ 37

6.3.2 Menu overview ...................................................................................................................... 38

6.3.3 Function description ............................................................................................................. 38

6.4 Further information on device configuration................................................................. 44

6.4.1 Quick Setup ........................................................................................................................... 44

6.4.2 Test........................................................................................................................................ 46

6.4.3 Protection of the device settings .......................................................................................... 47

6.4.4 Distance measurement ........................................................................................................ 48

6.4.5 Level measurement .............................................................................................................. 49

6.4.6 How to configure the device to measure volume or mass................................................... 49

6.4.7 Thresholds and parasitic signals.......................................................................................... 51

6.5 Status and error messages............................................................................................ 53

6.5.1 Status markers ..................................................................................................................... 53

6.5.2 Error handling....................................................................................................................... 54

7 Service 56

7.1 Spare parts availability...................................................................................................56

7.1.1 Part numbers for spare parts and accessories ................................................................... 56

7.2 Availability of services .................................................................................................... 57

7.3 Repairs............................................................................................................................ 57

7.4 Returning the device to the manufacturer..................................................................... 58

7.4.1 General information.............................................................................................................. 58

7.4.2 Form (for copying) to accompany a returned device............................................................ 59

7.5 Disposal .......................................................................................................................... 59

8 Technical data 60

8.1 Measuring principle........................................................................................................60

8.2 Technical data................................................................................................................. 61

8.3 Minimum power supply voltage ..................................................................................... 63

8.4 Measurement limits ....................................................................................................... 64

8.5 Dimensions and weights ................................................................................................ 65

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OPTIFLEX 1100 C

CONTENTS

9 Appendix 67

9.1 Order code ...................................................................................................................... 67

9.2 Glossary .......................................................................................................................... 68

10 Notes 71

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1 SAFETY INSTRUCTIONS

1.1 Intended use

CAUTION!

Responsibility for the use of the measuring devices with regard to suitability, intended use and corrosion resistance of the used materials against the measured fluid lies solely with the operator.

INFORMATION!

The manufacturer is not liable for any damage resulting from improper use or use for other than the intended purpose.

This TDR level transmitter has 3 probe versions:

Ø2 mm single cable probe

This device measures distance and level of liquids, pastes and slurries with a viscosity less than 10000 mPa.s. It can be installed on tanks.

Segmented coaxial probe

This device measures distance and level of liquids with a viscosity less than 500 mPa.s. It can be installed on tanks and open pits.

OPTIFLEX 1100 C

Ø4 mm single cable probe

This device measures distance and level of granulates and powders.

1.2 Certification

In accordance with the commitment to customer service and safety, the device described in this document meets the following safety requirements:

• Electromagnetic Compatibility (EMC) Directive 2004/108/EC in conjunction with EN 61326-1 (2006) and EN 61326-2-3 (2006)

1.3 Electromagnetic compatibility

The device design agrees with European Standard EN 61326-1 when installed in metallic tanks.

You can install the device on open-air tanks and tanks that are not made of metal. This agrees with Emissions requirements for industrial environments (class A). For data on Immunity requirements, refer to the note that follows.

CAUTION!

If you install a device with a cable probe in a non-metallic tank or open-air pit, a strong electromagnetic field near to the device can have an unwanted effect on the accuracy. Use a device with a coaxial probe for this type of installation.

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OPTIFLEX 1100 C

INFORMATION!

Device operation agrees with residential-class (class B) emissions and industrial-class for immunity requirements if the time constant (menu item 2.3.2 TIME CONST.) ≥ 3 seconds and:

•

the device has a single cable probe and is used in a closed tank made of metal or

•

the device has a coaxial probe.

1.4 Safety instructions from the manufacturer

1.4.1 Copyright and data protection

The contents of this document have been created with great care. Nevertheless, we provide no guarantee that the contents are correct, complete or up-to-date.

The contents and works in this document are subject to copyright. Contributions from third parties are identified as such. Reproduction, processing, dissemination and any type of use beyond what is permitted under copyright requires written authorisation from the respective author and/or the manufacturer.

The manufacturer tries always to observe the copyrights of others, and to draw on works created in-house or works in the public domain.

SAFETY INSTRUCTIONS 1

The collection of personal data (such as names, street addresses or e-mail addresses) in the manufacturer's documents is always on a voluntary basis whenever possible. Whenever feasible, it is always possible to make use of the offerings and services without providing any personal data.

We draw your attention to the fact that data transmission over the Internet (e.g. when communicating by e-mail) may involve gaps in security. It is not possible to protect such data completely against access by third parties.

We hereby expressly prohibit the use of the contact data published as part of our duty to publish an imprint for the purpose of sending us any advertising or informational materials that we have not expressly requested.

1.4.2 Disclaimer

The manufacturer will not be liable for any damage of any kind by using its product, including, but not limited to direct, indirect or incidental and consequential damages.

This disclaimer does not apply in case the manufacturer has acted on purpose or with gross negligence. In the event any applicable law does not allow such limitations on implied warranties or the exclusion of limitation of certain damages, you may, if such law applies to you, not be subject to some or all of the above disclaimer, exclusions or limitations.

Any product purchased from the manufacturer is warranted in accordance with the relevant product documentation and our Terms and Conditions of Sale.

The manufacturer reserves the right to alter the content of its documents, including this disclaimer in any way, at any time, for any reason, without prior notification, and will not be liable in any way for possible consequences of such changes.

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1 SAFETY INSTRUCTIONS

1.4.3 Product liability and warranty

The operator shall bear responsibility for the suitability of the device for the specific purpose. The manufacturer accepts no liability for the consequences of misuse by the operator. Improper installation and operation of the devices (systems) will cause the warranty to be void. The respective "Standard Terms and Conditions" which form the basis for the sales contract shall also apply.

1.4.4 Information concerning the documentation

To prevent any injury to the user or damage to the device it is essential that you read the information in this document and observe applicable national standards, safety requirements and accident prevention regulations.

If this document is not in your native language and if you have any problems understanding the text, we advise you to contact your local office for assistance. The manufacturer can not accept responsibility for any damage or injury caused by misunderstanding of the information in this document.

This document is provided to help you establish operating conditions, which will permit safe and efficient use of this device. Special considerations and precautions are also described in the document, which appear in the form of underneath icons.

OPTIFLEX 1100 C

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OPTIFLEX 1100 C

1.4.5 Warnings and symbols used

Safety warnings are indicated by the following symbols.

DANGER!

This information refers to the immediate danger when working with electricity.

DANGER!

This warning refers to the immediate danger of burns caused by heat or hot surfaces.

DANGER!

This warning refers to the immediate danger when using this device in a hazardous atmosphere.

DANGER!

These warnings must be observed without fail. Even partial disregard of this warning can lead to serious health problems and even death. There is also the risk of seriously damaging the device or parts of the operator's plant.

SAFETY INSTRUCTIONS 1

WARNING!

Disregarding this safety warning, even if only in part, poses the risk of serious health problems. There is also the risk of damaging the device or parts of the operator's plant.

CAUTION!

Disregarding these instructions can result in damage to the device or to parts of the operator's plant.

INFORMATION!

These instructions contain important information for the handling of the device.

LEGAL NOTICE!

This note contains information on statutory directives and standards.

• HANDLING

HANDLING

HANDLINGHANDLING

This symbol designates all instructions for actions to be carried out by the operator in the specified sequence.

i RESULT

RESULT

RESULTRESULT This symbol refers to all important consequences of the previous actions.

1.5 Safety instructions for the operator

WARNING!

In general, devices from the manufacturer may only be installed, commissioned, operated and maintained by properly trained and authorized personnel. This document is provided to help you establish operating conditions, which will permit safe and efficient use of this device.

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2 DEVICE DESCRIPTION

2.1 Device description

TDR level meters are designed exclusively to measure the distance and level of liquids, pastes, slurries, powders and granulates.

Your measuring device is supplied with a standard length of probe. If the probe length is larger than the tank height, you must adjust the length of the probe to the tank height before operation. A quick set-up procedure permits the device to operate correctly with the new probe length.

The following versions are available:

• Compact version with Ø2 mm / 0.08¨ single cable probe (for liquids)

• Compact version with coaxial probe (for liquids, maximum viscosity 500 mPa.s / 0.028 lb/in.s)

• Compact version with Ø4 mm / 0.15¨ single cable probe (for solids)

2.2 Nameplates

INFORMATION!

Look at the device nameplate to ensure that the device is delivered according to your order. Check for the correct supply voltage printed on the nameplate.

OPTIFLEX 1100 C

Figure 2-1: Nameplate

1 Cable entry size 2 Date of manufacture 3 Degree of ingress protection (according to EN 60529 / IEC 60529) 4 Order number 5 Type code (defined in order) 6 Model name and number 7 Company name and address

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OPTIFLEX 1100 C

3.1 Ø2 mm / 0.08¨ single cable probe (liquid applications)

3.1.1 Scope of delivery

INFORMATION!

Do a check of the packing list to make sure that you have all the elements given in the order.

INSTALLATION 3

Figure 3-1: Scope of delivery: device with Ø2 mm single cable probe option

1 Converter, process connection and probe 2 Counterweight 3 2 HC M6×5 screws for the counterweight 4 Probe assembly cover. For more data, refer to 5 Sticker: if you adjust the probe length, write the new value on the sticker 6 Quick Start 7 Strap wrench

3.1.2 Transport

Figure 3-2: How to hold the device

d > 100 mm / 4¨

How to turn or remove the signal converter

on page 28.

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3 INSTALLATION

3.1.3 How to assemble a single cable probe

Adjust the probe length to the tank height

Figure 3-3: How to assemble the Ø2 mm / 0.08¨ single cable probe: part 1

L = Probe length (thread stop to the bottom of the counterweight m = Counterweight length = 100 mm / 4¨ n = Cable insertion length = 15 mm / 0.6¨

OPTIFLEX 1100 C

INFORMATION!

The single cable probe measures between the top of the counterweight and the thread stop on the process connection.

• Measure the probe.

i Make sure that you include the length of the counterweight (m) minus the cable insertion

length (n).

• Mark the probe length necessary for your application on the cable.

• Cut the cable.

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OPTIFLEX 1100 C

Attach the counterweight

Figure 3-4: How to assemble the single cable probe: part 2

1 Single cable probe 2 Counterweight 3 2 HC M6×5 lock screws

CAUTION!

Make sure the cable is fully engaged in the probe counterweight.

INSTALLATION 3

• Attach the counterweight.

• Attach the lock screws to the counterweight. Tighten with a 3 mm Allen wrench.

i The device is prepared for installation on the tank.

If you decreased the probe length, you must enter the new value in the device configuration menu (NOTE: the device must have the LCD display option or the HMI service tool). For more data, refer to

Quick Setup

3.1.4 Mounting position

on page 44.

Figure 3-5: Cable probe: minimum distance from metallic walls and other metal objects

a ≥ 300 mm / 12¨

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3 INSTALLATION

Figure 3-6: Do not install the probe near to a product inlet

3.1.5 Installation in standpipes (stilling wells and bypass chambers)

Use a standpipe if there are too many other objects in the tank or the liquid is turbulent.

OPTIFLEX 1100 C

Figure 3-7: Installation recommendations for standpipes (stilling wells and bypass chambers)

1 Stilling well 2 Bypass chamber

INFORMATION!

Stilling wells are not necessary for devices with coaxial probes. But if there is a sudden change in diameter in the stilling well, we recommend that you install a device with a coaxial probe.

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OPTIFLEX 1100 C

CAUTION!

Installation requirements

•

The standpipe must be made of metal.

•

The standpipe must be straight. There must be no changes in diameter from the device process connection to the bottom of the standpipe.

•

The standpipe must be vertical.

•

Recommended surface roughness: <±0.1 mm / <±0.004¨.

•

Stilling well only: The bottom of the stilling well must be open.

•

Adjust the probe to the center of the standpipe.

•

Make sure that there are no deposits at the bottom of the standpipe which can cause blockage of the process connections.

•

Make sure that there is liquid in the standpipe.

Stilling wells Installation in tanks that contain one liquid

• Make sure that the stilling well has a vent above the maximum level.

• If the probe has a counterweight, make sure that there is enough space between the

counterweight and the wall of the stilling well.

INSTALLATION 3

Bypass chambers Installation next to tanks that contain one liquid

• The bypass chamber must have a process connection that is above the maximum level of liquid.

• The bypass chamber must have a process connection that is below the lowest measured level of liquid.

3.1.6 Horizontal cylindrical tanks

The installation requirements and procedures for vertical tanks are also applicable to horizontal cylindrical tanks.

CAUTION!

Calculate volume and mass values carefully for the strapping table. Volume does not increase in the same proportion as level.

Figure 3-8: How to install the device in a horizontal cylindrical tank

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3 INSTALLATION

3.2 Coaxial probe (low-viscosity liquid applications)

3.2.1 Scope of delivery

INFORMATION!

Do a check of the packing list to make sure that you have all the elements given in the order.

OPTIFLEX 1100 C

Figure 3-9: Scope of delivery: device with coaxial probe option

1 Converter, process connection and signal cable 2 HC M6×5 screws (1 screw per segment of tube, 3 screws for the last segment - supplied in a plastic sachet) 3 Quick Start 4 Probe assembly cover. For more data, refer to 5 Probe end cap 6 Sticker: if you adjust the probe length, write the new value on the sticker 7 Strap wrench 8 Disassembled segments of tube

3.2.2 Transport

Figure 3-10: How to hold the device

How to turn or remove the signal converter

on page 28.

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OPTIFLEX 1100 C

3.2.3 How to assemble the segmented coaxial probe

Attach the tube segments

INSTALLATION 3

Figure 3-11: How to assemble the segmented coaxial probe: part 1

1 Top segment of tube 2 Bottom segment of tube 3 1 HC M6×5 lock screw 4 Bonded plastic spacer

CAUTION!

•

After you tighten the lock screw on each segment of tube, it will not be possible to disassemble the coaxial probe.

•

If it is necessary to adjust the probe length, do not attach the lock screw to the last segment of tube!

• Put the signal cable into the first segment of tube. Make sure that the signal cable goes

through the center hole in the spacer.

• Attach the first segment of tube to the thread at the top of the signal cable. Tighten with a

17 mm open-end wrench.

• Attach the lock screw to the top of the tube. Tighten with a 3 mm Allen wrench.

• Do these steps again for each segment of tube, but do not attach the lock screw to the last

segment of tube.

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3 INSTALLATION

Adjust the probe length to the tank height

Figure 3-12: How to assemble the segmented coaxial probe: part 2

a = Delivered probe length (with all segments attached, but without the probe end cap) b = Length of tube needed = total probe length, L - 15 mm / 0.6¨

1 Coaxial probe: Last segment of the tube 2 Do not attach the lock screw to the last segment of tube! Make sure that the coaxial probe is the correct length for

the tank.

3 Scriber mark - to cut the tube to the correct length

OPTIFLEX 1100 C

CAUTION!

If it is necessary to decrease the length of the probe, do not attach the lock screw on the last segment of tube. Make sure the probe is the correct length for the tank. Add the probe end cap length (15 mm /

) to get the total length of the probe.

0.6

• Measure the probe (with all the segments attached).

• Mark the probe length necessary for your application on the tube.

• Remove the last segment of tube.

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OPTIFLEX 1100 C

Adjust the probe length to the tank height

Figure 3-13: How to assemble the segmented coaxial probe

1 Coaxial probe: Last segment of the tube 2 Probe end cap 3 1 HC M6×5 lock screw 4 Bonded plastic spacer

INSTALLATION 3

CAUTION!

Before you cut the tube, disassemble the last segment of tube from the coaxial probe and remove the signal cable. After you tighten the lock screw, it will not be possible to disassemble the coaxial probe.

• Cut the last segment of tube.

• Attach the last segment of tube.

• Attach the probe end cap 2 to the end of the tube. Tighten lock screw 3 with a 3 mm Allen

wrench.

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3 INSTALLATION

Make sure that the tension in the signal cable is correct

Figure 3-14: How to assemble the segmented coaxial probe: part 4

1 Coaxial probe: Signal cable 2 Coaxial probe: Probe end cap 3 2 HC M6×5 screws

OPTIFLEX 1100 C

• Pull the signal cable from the bottom of the last segment of tube. Apply 10 kgf / 22 lbf.

• Attach the screws for the signal cable to the probe end cap. Tighten with a 3 mm Allen wrench.

Cut the signal cable to the correct length

Figure 3-15: How to assemble the segmented coaxial probe: part 5

c = 20 mm / 0.8¨

1 Coaxial probe: bottom of the last segment of tube 2 Coaxial probe: signal cable

• Cut the signal cable 20 mm / 0.8¨ below the last segment of tube.

i The device is prepared for installation on the tank.

If you decreased the probe length, you must enter the new probe length in the device configuration menu (NOTE: the device must have the LCD display option or the HMI service tool). For more data, refer to

Quick Setup

on page 44.

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OPTIFLEX 1100 C

3.2.4 Mounting position

INSTALLATION 3

Figure 3-16: Coaxial probe: minimum distance from metallic walls and other metal objects

There is no minimum distance from the coaxial probe to metallic walls and other metal objects.

Figure 3-17: Do not install the probe near to a product inlet

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3 INSTALLATION

3.3 Ø4 mm / 0.15¨ single cable probe (solid applications)

3.3.1 Scope of delivery

INFORMATION!

Do a check of the packing list to make sure that you have all the elements given in the order.

OPTIFLEX 1100 C

Figure 3-18: Scope of delivery: device with Ø4 mm single cable probe option

1 Converter and process connection 2 Counterweight 3 4 HC M6×5 screws for the counterweight 4 Probe assembly cover. For more data, refer to 5 Sticker: if you adjust the probe length, write the new value on the sticker 6 Quick Start 7 Union nut 8 2 lock nuts 9 Probe 10 Strap wrench

3.3.2 Transport

How to turn or remove the signal converter

on page 28.

Figure 3-19: How to hold the device

d > 100 mm / 4¨

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