Operating Instructions
OPTISWITCH 5200 C, 5250 C
with two-wire output
Contents
Contents
1 About this document
1.1 Function .............................
1.2 Target group ..........................
1.3 Symbolism used .......................
2 For your safety
2.1 Authorised personnel....................
2.2 Appropriate use........................
2.3 Warning about misuse ...................
2.4 CE conformity .........................
2.5 SIL conformity .........................
2.6 Safety instructions for Ex areas ............
3 Product description
3.1 Configuration..........................
3.2 Principle of operation ....................
3.3 Operation ............................
3.4 Storage and transport ...................
4 Mounting
4.1 General instructions.....................
4.2 Mounting instructions....................
4
4
4
5
5
5
5
6
6
7
7
9
9
10
13
5 Connecting to voltage supply
5.1 Preparing the connection .................
5.2 Connection steps.......................
5.3 Wiring plan, single chamber housing.........
6 Set up
6.1 General..............................
6.2 Adjustment elements ....................
6.3 Function chart .........................
6.4 Recurring test and function test ............
7 Maintenance and fault rectification
7.1 Maintenance ..........................
7.2 Rectify faults ..........................
7.3 Instrument repair .......................
8 Dismounting
8.1 Dismounting procedure ..................
8.2 Disposal .............................
2 OPTISWITCH 5200 C, 5250 C - with two-wire output
16
16
17
20
21
21
22
25
25
26
27
27
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9 Supplement
9.1 Technical data.........................
9.2 Dimensions ...........................
Contents
28
32
30435-EN-060831
OPTISWITCH 5200 C, 5250 C - with two-wire 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. Please read this
manual before you start setup.
1.2 Target group
This operating instructions manual is directed to trained,
qualified 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.
Caution: If this warning is ignored, faults or
malfunctions can result.
Warning: If this warning is ignored, injury to persons and/or
serious damage to the instrument can result.
Danger: If this warning is ignored, serious injury to persons
and/or destruction of the instrument can result.
Ex applications
This symbol indicates special instructions for Ex applications.
l List
The dot set in front indicates a list with no implied sequence.
à Action
This arrow indicates a single action.
1 Sequence
Numbers set in front indicate successive steps in a procedure.
4 OPTISWITCH 5200 C, 5250 C - with two-wire output
30435-EN-060831
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 5200 C, 5250 C is a sensor for level detection.
Detailed information on the application range of OPTISWITCH
5200 C, 5250 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 5200 C, 5250 C is a high-tech instrument
requiring the strict observance of standard regulations and
guidelines. The user must take note of the safety instructions in
this operating instructions manual, the country-specific installation standards (e.g. the VDE regulations in Germany) as well
as all prevailing safety regulations and accident prevention
rules.
2.5 CE conformity
OPTISWITCH 5200 C, 5250 C is in CE conformity with EMC
(89/336/EWG), fulfils NAMUR recommendation NE 21 and is
in CE conformity with LVD (73/23/EWG).
Conformity has been judged according to the following
standards:
l EMC:
- Emission EN 61326/A1: 1998 (class B)
- Susceptibility EN 61326: 1997/A1:1998
l LVD: EN 61010-1: 1993
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OPTISWITCH 5200 C, 5250 C - with two-wire output 5
For your safety
2.6 SIL conformity
OPTISWITCH 5200 C, 5250 C fulfills the requirements of
functional safety according to IEC 61508/IEC 61511. You can
find further information in the supplementary instructions
manual "Safety Manual - Functional safety (SIL) OPTISWITCH
5XXX".
2.7 Safety instructions for Exareas
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.
6 OPTISWITCH 5200 C, 5250 C - with two-wire output
30435-EN-060831
3 Product description
3.1 Configuration
Product description
Scope of delivery
Components
The scope of delivery encompasses:
l OPTISWITCH 5200 C, 5250 C level sensor
l Documentation
- this operating instructions manual
- Ex specific safety instructions (with Ex versions), if
necessary further certificates
OPTISWITCH 5200 C, 5250 C consists of the following
components:
l Housing cover
l Housing with electronics
l process fitting with tuning fork
1
2
3
Fig. 1: OPTISWITCH 5200 C, 5250 C with plastic housing
1 Housing cover
2 Housing with electronics
3 Process fitting
3.2 Principle of operation
Area of application
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OPTISWITCH 5200 C, 5250 C - with two-wire output 7
OPTISWITCH 5200 C, 5250 C is a level sensor with tuning
fork for level detection.
Product description
It is designed for industrial use in all areas of process
technology and can be used in liquids.
Typical applications are overfill and dry run protection. With a
tuning fork of only 40 mm length, OPTISWITCH 5200 C, 5250
C can be also mounted, e.g. in pipelines from DN 25. The
small tuning fork allows use in vessels, tanks and pipes.
Thanks to its simple and robust measuring system, OPTISWITCH 5200 C, 5250 C is virtually unaffected by the
chemical and physical properties of the liquid.
It functions even under difficult conditions such as turbulence,
air bubbles, foam generation, buildup, strong external vibration
or changing products.
Fault monitoring
The electronics module of OPTISWITCH 5200 C, 5250 C
continuously monitors via frequency evaluation the following
criteria:
l Strong corrosion or damage on the tuning fork
l loss of vibration
l Line break to the piezo drive
If one of these faults is detected, the electronics signals it via a
defined current to the signal conditioning instrument. The
connection cable to the sensor is also monitored on line break
and short-circuit.
Physical principle
The tuning fork is piezoelectrically energised and vibrates at its
mechanical resonance frequency of approx. 1200 Hz. The
piezos are fastened mechanically and are hence not subject to
temperature shock limitations. When the tuning fork is
submerged in the product, the frequency changes. This
change is detected by the integrated oscillator, transferred to
the signal conditioning instrument as current value and
converted into a switching command.
Power supply
Depending on your requirements, OPTISWITCH 5200 C, 5250
C with two-wire electronics can be connected to different
signal conditioning instruments. Compatible signal conditioning instruments are listed under "Technical data".
The exact range of the power supply is stated in the "Technical
data" in the "Supplement".
8 OPTISWITCH 5200 C, 5250 C - with two-wire output
30435-EN-060831
Product description
3.3 Operation
The switching condition of OPTISWITCH 5200 C, 5250 C with
plastic housing can be checked when the housing is closed
(signal lamp). With the basic setting, products with a density
>0.7 g/cm³ (>0.025 lbs/in³) can be detected. The instrument
can be adapted if products with lower density should be
measured.
On the electronics module you will find the following indicating
and adjustment elements:
l signal lamp for indication of the switching condition (green/
red)
l DIL switch for adaptation to the product density
3.4 Storage and transport
Packaging
Storage and transport tem-
perature
Your instrument was protected by packaging during transport.
Its capacity to handle normal loads during transport is assured
by a test according 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.
l Storage and transport temperature see "Supplement -
Technical data - Ambient conditions"
l Relative humidity 20 … 85 %
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OPTISWITCH 5200 C, 5250 C - with two-wire output 9
Mounting
4 Mounting
4.1 General instructions
Switching point
In general, OPTISWITCH 5200 C, 5250 C can 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 mounting. The switching point
refers to water with the basic setting of the sensitivity switch
>=0.7 g/cm³ (>=0.025 lbs/in³). When mounting OPTISWITCH
5200 C, 5250 C, make sure that this marking is at the height of
the requested switching point. Keep in mind that the switching
point of the instrument is shifted if the medium has a density
other than water - water =1 g/cm³ (=0.036 lbs/in³). For
products <0.7 g/cm³ (<0.025 lbs/in³)
and >0.5 g/cm³
(>0.018 lbs/in³) the density switch must be set to >=0.5 g/cm³.
2
1
4
3
Fig. 2: Vertical mounting
1 Switching point approx. 13 mm (approx. 0.51 in)
2 Switching point with lower density
3 Switching point with higher density
4 Switching point approx. 27 mm (approx. 1.06 in)
10 OPTISWITCH 5200 C, 5250 C - with two-wire output
30435-EN-060831
Mounting
1
Fig. 3: Horizontal mounting
1 Switching point
2
1
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
With flange versions, the fork is directed to the flange holes in
the following way.
Fig. 5: Fork position with flange versions
Moisture
Use the recommended cables (see chapter "Connecting to
power supply") and tighten the cable gland.
You can give your OPTISWITCH 5200 C, 5250 C additional
protection against moisture penetration by leading the connection cable downward in front of the cable entry. Rain and
30435-EN-060831
OPTISWITCH 5200 C, 5250 C - with two-wire output 11
Mounting
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.
Fig. 6: Measures against moisture penetration
Transport
Pressure/Vacuum
Handling
Do not hold OPTISWITCH 5200 C, 5250 C on the tuning fork.
Particularly with flange or tube versions, the tuning fork can be
damaged by the instrument weight. Transport 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 max. permissible pressure is stated in the "Technical
data" in the "Supplement" or on the type label of the sensor.
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 in the instrument!
Applying tightening force on the housing can damage its
internal mechanical parts.
To screw in, use the hexagon above the thread.
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12 OPTISWITCH 5200 C, 5250 C - with two-wire output
4.2 Mounting instructions
Mounting
Welded socket
OPTISWITCH 5200 C, 5250 C has a defined thread starting
point. This means that every OPTISWITCH 5200 C, 5250 C is
in the same fork position after being screwed in. Remove
therefore the supplied seal from the thread of OPTISWITCH
5200 C, 5250 C. This seal is not required when using a welded
socket with O-ring in front.
Keep in mind that this welded socket is not suitable for coated
instrument versions.
Screw OPTISWITCH 5200 C, 5250 C completely into the
welded socket. The later position can be determined already
before welding. Mark the appropriate position of the welded
socket. Before welding, unscrew OPTISWITCH 5200 C, 5250
C and remove the rubber ring from the welded socket. The
welded socket has a marking (notch). Weld the socket with the
notch facing upward, or in case of pipelines, aligned with the
direction of flow.
1
Fig. 7: Marking on the welded socket
1 Marking
Adhesive products
In case of horizontal mounting in adhesive and viscous
products, the surfaces of the tuning fork should be vertical in
order to reduce buildup on the tuning fork. On the screwed
version you will find a marking on the hexagon. With this, you
can check the position of the tuning fork when screwing it in.
When the hexagon touches the seal, the thread can still be
turned by approx. half a turn. This is sufficient to reach the
recommended installation position.
With flange versions, the fork is directed to the flange holes.
30435-EN-060831
OPTISWITCH 5200 C, 5250 C - with two-wire output 13
Mounting
When used in adhesive and viscous products, the tuning fork
should protrude into the vessel to avoid buildup. For that
reason, sockets for flanges and mounting bosses should be
avoided when mounting horizontally.
Inflowing medium
Flows
If OPTISWITCH 5200 C, 5250 C is mounted in the filling
stream, unwanted switching signals may be generated. Mount
OPTISWITCH 5200 C, 5250 C at a location in the vessel
where no disturbing influence from e.g. filling openings,
agitators etc. can occur.
This applies particularly to instrument types with long
extension tube.
Fig. 8: Inflowing medium
To minimise flow resistance caused by the tuning fork,
OPTISWITCH 5200 C, 5250 C should be mounted in such a
way that the surfaces of the blades are parallel to the product
movement.
Agitators
Due to agitators, vibrations or similar, the level switch can be
subjected to strong lateral forces. For this reason, do not use
an overly long extension tube for OPTISWITCH 5200 C, 5250
C, but check if you can mount an OPTISWITCH 5100 C,
5150 C level switch on the side of the vessel in horizontal
position.
Extreme vibration caused by the process or the equipment, e.
g. agitators or turbulence in the vessel can cause the extension
tube of OPTISWITCH 5200 C, 5250 C to vibrate in resonance.
This leads to increased stress on the upper weld joint. Should
14 OPTISWITCH 5200 C, 5250 C - with two-wire output
30435-EN-060831
Mounting
a longer tube version be necessary, you can provide a suitable
support or guy directly above the tuning fork to secure the
extension tube.
This measure applies particularly to applications in Ex areas
category 1G or WHG. Make sure that the tube is not bent by
this measure.
Fig. 9: Lateral straining of OPTISWITCH 5200 C, 5250 C
Enamel coating
Instruments with enamel coating should be treated very
carefully and shocks should be avoided. Unpack OPTI-
SWITCH 5200 C, 5250 C directly before installation. Insert
OPTISWITCH 5200 C, 5250 C carefully into the vessel
opening and avoid touching any sharp vessel parts.
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OPTISWITCH 5200 C, 5250 C - with two-wire output 15
Connecting to voltage supply
5 Connecting to voltage supply
5.1 Preparing the connection
Note safety instructions
Take note of safety
instructions for Ex
applications
Select power supply
Selecting the connection ca-
ble
Generally not the following safety instructions:
l Connect only in the complete absence of line voltage
In hazardous areas you should take note of the appropriate
regulations, conformity and type approval certificates of the
sensors and power supply units.
Connect the power supply according to the following diagrams.
Take note of the general installation regulations. As a rule,
connect OPTISWITCH 5200 C, 5250 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 5200 C, 5250 C is connected with standard
cable with round 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 5200 C, 5250 C.
Select connection
cable for Ex applications
Take note of the corresponding installation regulations for Ex
applications.
5.2 Connection steps
With Ex instruments, the housing cover may only be opened if
there is no explosive atmosphere present.
Proceed as follows:
1 Unscrew the housing cover
2 Loosen compression nut of the cable entry
16 OPTISWITCH 5200 C, 5250 C - with two-wire output
30435-EN-060831
Housing overview
Connecting to voltage supply
3 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
4 Insert the cable into the sensor through the cable entry
5 Open the terminals with a screwdriver
6 Insert the wire ends into the open terminals according to
the wiring plan
7 Tighten the terminals with a screwdriver
8 Check the hold of the wires in the terminals by lightly
pulling on them
9 Tighten the compression nut of the cable entry, the seal
ring must completely encircle the cable
10 Screw the housing cover back on
The electrical connection is hence finished.
5.3 Wiring plan, single chamber housing
The following illustrations apply to the non-Ex as well as to the
EEx d version.
44
1
Fig. 10: Material versions, single chamber housing
1 Plastic (not with EExd)
2 Aluminium
3 Stainless steel (not with EExd)
4 Filter element for pressure compensation (not with EExd)
30435-EN-060831
OPTISWITCH 5200 C, 5250 C - with two-wire output 17
2 3
4
Connecting to voltage supply
Electronics and connection
compartment
SW E60Z
1
11-36V DC
+
12
0,5 g / cm
0,7 g / cm
3
3
4
Fig. 11: Electronics and connection compartment, single chamber housing
1 Control lamp
2 DIL switch for sensitivity adjustment
3 Ground terminal
4 Screwed terminals
2
3
Wiring plan
We recommend connecting OPTISWITCH 5200 C, 5250 C in
such a way that the switching circuit is open when there is a
level signal, line break or failure (safe condition).
For connection to a signal conditioning instrument dto. Ex,
WHG. The sensor is powered by the connected signal
conditioning instrument. Further information is available in the
Technical data in the Supplement, Ex-technical data are
available in the supplied safety information manual.
The wiring example is applicable for all suitable signal
conditioning instruments.
The control lamp on OPTISWITCH 5200 C, 5250 C lights in
general
l red - with covered tuning fork
l green - with uncovered tuning fork
Take note of the operating instructions manual of the signal
conditioning instrument. Suitable signal conditioning instruments are listed in the Technical data.
If OPTISWITCH 5200 C, 5250 C is used in Ex areas as part of
an overfill protection system acc. to WHG, take note for the
regulations in the safety instructions and conformity certifi-
18 OPTISWITCH 5200 C, 5250 C - with two-wire output
30435-EN-060831
Connecting to voltage supply
cates. If OPTISWITCH with oscillator SW E60ZEX, SW E60Z
EX E1 should be operated directly on the analogue input of a
PLC, a suitable safety barrier should be connected.
+-
1 2
4321
Fig. 12: Wiring plan, single chamber housing
30435-EN-060831
OPTISWITCH 5200 C, 5250 C - with two-wire output 19
Set up
6 Set up
6.1 General
The numbers in brackets refer to the following illustrations.
Function/Configuration
The switching status of the electronics can be checked when
the cover of the plastic housing is closed (signal lamp). In the
basic setting, products with density > 0.7 g/cm³ (0.025 lbs/in³)
can be detected. For products with lower density, the switch
must be set to > 0.5 g/cm³ (0.018 lbs/in³).
On the electronics module you will find the following indicating
and adjustment elements:
l Signal lamp (1)
l DIL switch for sensitivity adjustment (2)
Mode switch (A/B)
On the signal conditioning instrument via the signal conditioning instrument (only permissible in mode A when used
acc. to WHG).
The switching condition can be changed with the A/B switch.
You can set the required mode acc. to the "Function chart" (A -
max. detection or overfill protection, B - min. detection or dry
run protection). The integration time can also be modified on
the signal conditioning instrument.
Note:
For test purposes, immerse the tuning fork of OPTISWITCH
5200 C, 5250 C always in liquids. Do not test the function of
OPTISWITCH 5200 C, 5250 C with the hand. This can
damage the sensor.
20 OPTISWITCH 5200 C, 5250 C - with two-wire output
30435-EN-060831
6.2 Adjustment elements
2
1
Fig. 13: Oscillator SW E60Z - two-wire output
1 Signal lamp (LED)
2 DIL switch for sensitivity adjustment
Set up
1
2
Signal lamp (1)
Sensitivity adjustment (2)
Control lamp (LED) for indication of the switching condition
l green = tuning fork uncovered
l red = tuning fork covered
l off = failure
With this DIL switch (2) you can set the switching point to
liquids having a density between 0.5 and 0.7 g/cm³ (0.018 and
0.025 lbs/in³). With the basic setting, liquids with a density of
>0.7 g/cm³ (>0.025 lbs/in³) can be detected. In liquids with
lower density, you must set the switch to >0.5 g/cm³
(>0.018 lbs/in³). The specifications for the position of the
switching point relate to water - density value 1.0 g/cm³
(0.
036 lbs/in³). In products with a different density, the
switching point will shift in the direction of the housing or tuning
fork end depending on the density and type of installation.
6.3 Function chart
The following chart provides an overview of the switching
conditions depending on the adjusted mode and level.
30435-EN-060831
OPTISWITCH 5200 C, 5250 C - with two-wire output 21
Set up
Mode on
the signal
conditioning instrument
Mode A
Overfill
protection
Mode A
Overfill
protection
Mode B
Dry run
protection
Mode B
Dry run
protection
Fault signal
(mode A/B)
Level Signal
current Sensor
approx.
8 mA
approx.
16 mA
approx.
16 mA
approx.
8 mA
any approx.
1.8 mA
Analogue
input con-
1)
trol
>3.6 mA
<11 mA
>13 mA
<21 mA
>13 mA
<21 mA
>3.6 mA
<11 mA
<=3.6 mA
>=21.6 mA
Signal
lamp sensor
Green
red
red
Green
Signal
lamp signal
conditioning
instrument
6.4 Recurring test and function test
Acc. to WHG and IEC 61508. The implementation of the
recurring test acc. to WHG is stipulated in the general type
approval, item 8.
Take note of the overwhelming approvals, if OPTISWITCH
5200 C, 5250 CEx is used as part of an overfill protection
system according to WHG.
OPTISWITCH 5200 C, 5250 CEx in conjunction with an SU
501 (Ex) is qualified in mode A (overfill protection) for use in
measuring chains of SIL2 acc. to IEC 61508 (redundant, SIL3).
1)
Electronics directly evaluated via the analogue input of a control system
(without signal conditioning instrument)
22 OPTISWITCH 5200 C, 5250 C - with two-wire output
30435-EN-060831
Set up
WHG
SIL
Recurring test and function
test
The following instrument combinations meet the requirements
acc. to WHG:
OPTISWITCH 5200 C, 5250 CEXwith
l Oscillator SWE60ZEX
l signal conditioning instrument SU 501 (Ex) or PLC
The following instrument combinations meet the requirements
according to SIL:
OPTISWITCH 5200 C, 5250 CEX
l Oscillator SW E60Z (EX)
l signal conditioning instrument SU 501 (Ex)
The recurring test according to WHG and the function test
according to IEC 61508 can be carried out by pushing the test
key on the signal conditioning instrument or by briefly (> 2
seconds) interrupting the cable to the sensor. The correct
sequence of the switching conditions must be monitored via
the two signal lamps on the signal conditioning instrument as
well as the connected systems. The sensor must neither be
removed nor must a response be triggered by filling the vessel.
This applies to OPTISWITCH 5200 C, 5250 C with two-wire
oscillator SW E60ZEX.
If you are subject to the WHG regulations, you can carry out
the function test with the outputted current values also directly
via a PLC or a process control system.
The implementation and switching sequence of the function
test is described also in the operating instructions manual of
the appropriate signal conditioning instrument.
Test key on the signal conditioning instrument
A function test can be carried out for measuring systems in
conjunction with the two-wire oscillator SW E60ZEX. For this
the integration time must be set to 0.5 s. The signal
conditioning instrument has an integrated test key. The test
key is recessed in the front plate of the signal conditioning
instrument. Push the test key for > 2 seconds with a suitable
object (screwdriver
, pen, etc.).
For WHG the following is also applicable: If OPTISWITCH
5200 C, 5250 C is connected to a processing system or a PLC,
you have to interrupt the connection cable to the sensor for > 2
seconds.
After releasing the test key or interrupting the connection cable
to the sensor, the complete measuring system can be checked
30435-EN-060831
OPTISWITCH 5200 C, 5250 C - with two-wire output 23
Set up
on correct function. The following operating conditions are
simulated during the test:
l Fault signal
l Empty signal
l Full signal
Check if all three switching conditions occur in the correct
sequence and the stated time period. If this is not the case,
there is a fault in the measuring system (see also the operating
instructions manual of the signal conditioning instrument).
Keep in mind that connected instruments are activated during
the function test. By doing this, you can check the correct
function of the measuring system.
Test procedure
1. Fault signal
(approx. 3 s)
2. Empty signal
(approx. 1.5 s)
3. Full signal
(approx. 1.5 s)
4. Return to the actual
operating condition
(after releasing the test key)
Sensor
current Sensor
<2.0 mA currentless currentless
approx. 8mAenergized currentless energized
approx. 16mAcurrentless energized
Level relay A -
overfill
protection
Level relay B - dry
run protection
Signal
lamp A -
Overfill
protection
Signal
lamp B -
Dry run
protection
Fail safe
relay
currentless
energized
Note:
Mode B is not permissible when used as part of an overfill
protection system acc. to WHG and use in measuring chains
acc. to IEC 61508.
Control
lamp
You can carry out the function test with the outputted current
values also directly with a PLC or a process control system
(WHG).
24 OPTISWITCH 5200 C, 5250 C - with two-wire output
30435-EN-060831
Maintenance and fault rectification
7 Maintenance and fault rectification
7.1 Maintenance
When used as directed in normal operation, OPTISWITCH
5200 C, 5250 C is completely maintenance free.
7.2 Rectify faults
Causes of malfunction
Fault rectification
Checking the switching signal
OPTISWITCH 5200 C, 5250 C offers maximum reliability.
Nevertheless faults can occur during operation. These may be
caused by the following, e.g.:
l Sensor
l Process
l Power supply
l Signal processing
The first measure to be taken is to check the output signal. In
many cases, the causes can be determined this way and the
faults rectified.
? OPTISWITCH 5200 C, 5250 C signals "covered" when the
vibrating element is not submerged (overfill protection)
? OPTISWITCH 5200 C, 5250 C signals "uncovered" when
the vibrating element is submerged (dry run protection)
l Supply voltage too low
à Check the power supply
l Electronics defective
à Press the mode switch (min./max.). 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.
à Push the mode switch. If the instrument then does not
change the mode, the oscillator may be defective.
Exchange the oscillator.
à Check if there is buildup on the vibrating element, and if
so, remove it.
l Unfavourable installation location
à Mount the instrument at a location in the vessel where
no dead zones or air bubbles can form.
30435-EN-060831
OPTISWITCH 5200 C, 5250 C - with two-wire output 25
Maintenance and fault rectification
l Wrong mode selected
à Set the correct mode on the mode switch (max.: overfill
protection; min.: dry run protection). Wiring should be
carried out according to the quiescent current principle.
? Signal lamp flashes red
l Electronics has detected a failure
à Exchange instrument or return instrument for repair
? The signal lamp flashes alternately red and green
l instrument defective
à Exchange instrument or return instrument for repair
7.3 Instrument repair
If a repair is necessary, please proceed as follows:
You can download a return form from our website
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.
l Print and fill out one form per instrument
l Clean the instrument and pack it damage-proof
l Attach the completed form and possibly also a safety data
sheet to the instrument
http://www.
26 OPTISWITCH 5200 C, 5250 C - with two-wire output
30435-EN-060831
Dismounting
8 Dismounting
8.1 Dismounting procedure
Warning:
Before dismounting, be aware of dangerous process conditions such as e.g. pressure in the vessel, high temperatures,
corrosive or toxic products etc.
Take note of chapters "Mounting" and "Connecting to power
supply" and carry out the listed steps in reverse order.
With Ex instruments, the housing cover may only be opened if
there is no explosive atmosphere present.
8.2 Disposal
The instrument consists of materials which can be recycled by
specialised recycling companies. We use recyclable materials
and have designed the electronic modules to be easily
separable.
WEEE directive 2002/96/EG
This instrument is not subject to the WEEE directive 2002/96/
EG and the respective national laws (in Germany, e.g.
ElektroG). Pass the instrument directly on to a specialised
recycling company and do not use the municipal collecting
points. These may be used only for privately used products
according to the WEEE directive.
Correct disposal avoids negative effects to persons and
environment and ensures recycling of useful raw materials.
Materials: see "Technical data"
If you cannot dispose of the instrument properly, please
contact us about disposal methods or return.
30435-EN-060831
OPTISWITCH 5200 C, 5250 C - with two-wire output 27
Supplement
9 Supplement
9.1 Technical data
General data
Material 316L corresponds to 1.4404 or 1.4435
Materials, wetted parts
- Process fitting - thread 316L, Hastelloy C4 (2.4602)
- Process fitting - flange 316L, 316L with Hastelloy C4 plated, enam-
elled steel, 316L with ECTFE coated, 316L with
PFA coated
- Process seal Klingersil C-4400
- Tuning fork 316L, Hastelloy C4 (2.4610)
- Extension tube ø 21.
Materials, non-wetted parts
- Housing Plastic PBT (Polyester), Alu die-casting pow-
- Seal ring between housing and
housing cover
- waveguide in the housing cover PMMA (Makrolon)
- Ground terminal 316L
- Temperature adapter (optional
- Gas-tight leadthrough (optional) 316L/glass
3 mm (0.84 in) 316L, Hastelloy C4 (2.4610), Hastelloy C4
(2.4610) enamelled, 316L with ECTFE coating,
316L with PFA coating
der-coated, 316L
NBR (stainless steel housing), silicone (Alu/
plastic housing)
) 316L
Lengths
- 316L, Hastelloy C4 (2.4610) 80 … 6000 mm (3 … 236 in)
- Hastelloy C4 (2.4610) enamelled 80 … 1500 mm (3 … 59 in)
- 316L, ECTFE coated 80 … 3000 mm (3 … 118 in)
- 316L, PFA coated 80 … 3000 mm (3 … 118 in)
Weights
- Plastic housing 760 g (
- Aluminium housing 1170 g (41 oz)
- Stainless steel housing 1530 g (54 oz)
- Tube extension approx. 110 g/m (1.2 oz/ft)
28 OPTISWITCH 5200 C, 5250 C - with two-wire output
27 oz)
30435-EN-060831
Supplement
Layer thickness
- Enamel approx. 0.8 mm (0.03 in)
- ECTFE approx. 0.5 mm (approx. 0.02 in)
- PFA approx. 0.5 mm (approx. 0.02 in)
Surface quality
- Standard R
- Hygienic version 3A (OPTISWITCH
approx. 3 µm (approx. 1.18-4in)
a
<0.8 µm (<3.15-5in)
R
a
5250 C)
Process fittings
- Thread G¾ A, ¾ NPT, G1 A, 1 NPT
- Flanges DIN from DN 25, ANSI from 1"
- hygienic fittings Bolting DN 40 PN 40, Tri-Clamp 1", Tri-Clamp
1½" PN 10, conus DN 25 PN 40, Tuchenhagen
Varivent DN 50 PN 10
High voltage test (enamel) max. 5 KV
Gas-tight leadthrough (optional)
-6
- leakage rate <10
mbar l/s
- pressure resistance PN 64
- hygienic fittings Bolting DN 40 PN 40, Tri-Clamp 1", Tri-Clamp
1½" PN 10, conus DN 25 PN 40, Tuchenhagen
Varivent DN 50 PN 10
Output variable
Output Two-wire output
Output signal
- empty (uncovered) approx. 8 mA
- full (covered) approx. 16 mA
- Fault signal <2.0 mA
Possible signal conditioning instruments SU 501 (Ex)
Modes (adjustable via the signal conditioning instrument
)
- AMax. detection or overflow/overfill protection
- BMin. detection or dry run protection
Measuring accuracy
Hysteresis approx. 2 mm (0.08 in) with vertical installation
Integration time approx. 500 ms
Frequency approx. 1200 Hz
30435-EN-060831
OPTISWITCH 5200 C, 5250 C - with two-wire output 29
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 Limit level of liquids
Process pressure -1 … 64 bar (-14.5 … 938 psi) depending on
the process fitting, e.g. flange
OPTISWITCH 5200 C, 5250 C of 316L/
-50 … +150 °C (-58 … +302 °F
)
Hastelloy C4 (2.4610)
Process temperature (thread or flange
temperature) with temperature adapter
(option)
- OPTISWITCH 5200 C, 5250 C of
-50 … +250 °C (-58 … +482 °F)
316L/Hastelloy C4
- OPTISWITCH 5200 C, 5250 C
-50 … +200 °C (-58 … +392 °F)
enamelled
- OPTISWITCH 5200 C, 5250 C with
-50 … +150 °C (-58 … +302 °F)
ECTFE coating
- OPTISWITCH 5200 C, 5250 C with
-50 … +150 °C (-58 … +302 °F)
PFA coating
2
70˚C
(158˚F)
40˚C
(104˚F)
0˚C
(32˚F)
-50˚C
(-58˚F)
-40˚C
(-40˚F)
Fig. 14: Ambient temperature - Product temperature
1 Product temperature
2 Ambient temperature
3 Temperature range with temperature adapter
50˚C
(122˚F)
100˚C
(212˚F)
150˚C
(302˚F)
3
200˚C
(392˚F)
250˚C
(482˚F)
1
Viscosity - dynamic 0.1 … 10,000 mPas(requirement: with density
1)
Density 0.7 … 2.5 g/cm³ (0.025 … 0.09 lbs/in³);
30 OPTISWITCH 5200 C, 5250 C - with two-wire output
30435-EN-060831
Supplement
0.5 … 2.5 g/cm³ (0.018 … 0.09 lbs/in³) by
switching over
Electromechanical data
Cable entry/plug
2)
- Single chamber housing l 1x cable entry M20x1.5 (cable-ø 5 … 9 mm),
1x blind stopper M20x1.5
or:
l 1x closing cap ½ NPT, 1x blind plug ½ NPT
or:
l 1x plug (depending on the version), 1x blind
plug M20x1.5
Screw terminals for wire cross-section up to 1.5 mm²
(0.0023 in²)
Adjustment elements
Sensitivity switch
- 0.50.5 … 2.5 g/cm³ (0.018 … 0.9 oz/in³)
- 0.70.7 … 2.5 g/cm³ (0.025 … 0.9 oz/in³)
Voltage supply
Supply voltage 11 … 36 VDC(via the signal conditioning
instrument)
E
lectrical protective measures
Protection IP 66/IP 67
Overvoltage category III
Protection class II
Approvals
3)
ATEX II 1G, 1/2G, 2GEExiaIIC T6
ATEX II 1/2G, 2GEExd d IIC T6
4)
Overfill protection acc. to WHG
Ship approvals
2)
Depending on the version M12x1, according to DIN 43650, Harting, Amphenol-Tuchel, 7/8" FF.
3)
Deviating data in Ex applications: see separate safety instructions.
4)
Only with Aluminium housing.
30435-EN-060831
OPTISWITCH 5200 C, 5250 C - with two-wire output 31
/
/
/
M20x1,5
½
/
½
/
½
Supplement
9.2 Dimensions
Housing
~ 69mm
23
(2
/32")
Fig. 15: Housing versions
1 Plastic housing
2 Stainless steel housing
3 Aluminium housing
ø 77mm
1
(3
/32")
M20x1,5
~ 116mm
9
/16")
(4
ø 84mm
(3
5
/16")
4
1
4
~ 69mm
23
/32")
(2
2
4
M20x1,5
ø 77mm
1
(3
/32")
4
4
32 OPTISWITCH 5200 C, 5250 C - with two-wire output
30435-EN-060831
OPTISWITCH 5200 C, 5250 C
")
64
/
47
18,5mm
(
32 (G3/4A, 3/4"NPT)
41 (G1A, 1"NPT)
G3/4A, 3/4"NPT
G1A, 1"NPT
")
64
/
27
36mm (1
")
4
/
1
57mm
(2
Supplement
1 2 3
L
")
4
/
3
19mm
ø33,7mm
21
/64")
(1
(
")
32
/
31
50mm
(1
L
4 5
L
Fig. 16: OPTISWITCH 5200 C, 5250 C, threaded version
1 Thread
2 Tri-Clamp
3 Cone DN 25
4 Bolting DN 40
5 Flange
6 Gas-tight leadthrough
7 Temperature adapter
L = Sensor length, see "Technical data"
L
L
")
32
/
11
34mm (1
")
64
/
57
175mm (6
7
6
30435-EN-060831
OPTISWITCH 5200 C, 5250 C - with two-wire output 33
Supplement
34 OPTISWITCH 5200 C, 5250 C - with two-wire output
30435-EN-060831
Supplement
30435-EN-060831
OPTISWITCH 5200 C, 5250 C - with two-wire output 35
Subject to change without notice
30435-EN-060831
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