• The images shown in this manual may differ from the actual instrument / housing in terms of dimensions, color and design. Please refer to GA drawings
for dimensional details.
• Values (of performance) described in this manual were obtained under ideal testing conditions. Hence, they may differ under industrial environment and
settings.
General Instructions
• Instrument shouldn’t block the material filling inlet.
• Secure the cover of housing tightly. Tighten the cable glands. For side mounting, the cable glands should point downwards.
• For side mounting, provide a baffle to prevent the material from falling on the probe.
• Make all electrical connections as instructed in the manual. DO NOT power on the device before verifying the connections.
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User Manual & Datasheet V 2.3
1Introduction
Vital is a vibrating fork level limit switch for free-flowing
solids having a maximum granule size ≤ 12 mm. It is suitable for level detection in silos, bins, hoppers, etc. where
the process temperature ranges between 0◦C to +150◦C.
It has no moving parts and can replace rotating paddle level
switch in most applications.
Figure 1: Vital Product Image
2Operating Principle
A specially shaped tuning fork is kept vibrating using
piezo-electric elements. The oscillations of the fork dampen
when it comes in contact with the application material. The
loss of oscillation amplitude is detected and used for switching the output. The output contacts of the relay are in turn
used for annunciation and / or control.
• Self-diagnosis.
• External LED indication available with WL option
• Independent of material’s electrical properties.
• Compact instrument, minimum tines length of 100 mm.
• No moving parts, no wear and tear, maintenance-free.
• IP68 Protection, as per IS 13947.
• Polished tines ideal for hygienic applications with FB
option
4Applications
• Fast Packaging machines for powders, granuales
• PET / PVC chips with underwater detection
• Powders, sand & sugar
• Iron ore, sinters & pulverized coal
• Dry sand & Fly-ash
• Food grains
• Cement
Figure 2: Description of Parts
3Features
• Low Power Consumption: Less heat, Long life.
• Fast switching minimum of 0.5s availbale on request
with FS option
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User Manual & Datasheet V 2.3
5Electrical Specifications
Please refer to Table 1 for Electrical Specifications.
PARAMETERVALUE
Input Power Supply18 - 55V DC and 90 - 265V AC at 50Hz on same terminal
Output
• Relay DPDT
• Relay SPDT, PNP
Power Consumption
• 1.5W (SPDT, PNP) at 24 V
• 2.2W (DPDT) at 24 V
SwitchingSingle-point level switching
Switching IndicationBi-Color LED on the electronics insert
• Green - Normal
• Red - Alarm
External LED between the cable glands(with option WL)
• Blue - Normal
• Red - Alarm
Fail-safeField Selectable
• Open - Fail-safe High (For High Level)
• Close - Fail-safe Low (For Low Level)
Time Delay Settings1 - 25 seconds (For both, Covered and Uncovered Delays)
Operating Temperature
• Ambient Temperature: 0
• Process Temperature: 0
Relay Rating6 Amp at 230 VAC
Table 1: Electrical Specifications
◦
C to 65◦C
◦
C to 100◦C with option HT
6Application Specifications
Please refer to Table 2 for Application Specifications.
PARAMETERVALUE
Sensitivity
• Dense Media/Build Up - 1
• Ligthter Media - 5
Density of media (min)0.7 gm/cm
Grain SizeA maximum of 12mm
Response Time with ’NS’ option
• Cover Delay : 1-2 second
• Uncover Delay : 1-3 seconds
3
Response Time with ’FS’ option
Sapcon Instruments Pvt.Ltd.
• Cover Delay : 1 second
• Uncover Delay : 0.8 seconds
Table 2: Application Specifications
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User Manual & Datasheet V 2.3
7Mechanical Specifications
Please refer to Table 3 for Mechanical Specifications.
PARAMETERVALUE
Housing
• SCUTE: Pressure die-cast aluminium weatherproof
(Rating IP-68)
• FP2C: Cast aluminium, weatherproof & flameproof,
powder coated, suitable for Gas Groups IIA, IIB & IIC
as per IS-2148
Electrical ConnectorPG-13.5, 1/2" BSP DC Glands, 1/2” NPT DC Glands
Mounting
• Screwed - 1”/1 1/2” BSP/NTP(M)
• Flanged - As per your specifications
• Material - MS (Plated), SS
Sensing ForkSS 316
Extension PipeGI (Galvanized Iron) / SS-304 / SS -316
Table 3: Mechanical Specifications
8Installation & Handling Guidelines
The fork should be installed in horizontal or vertical position. The following image displays different allowable installation
positions. Observe that when installed directly under the material inlet source, a canopy called baffle of appropriate strength
and size should be welded right above the fork as shown.
While installing the instrument, please take care of the following points:
• The instrument shouldn’t block the material filling inlet.
• Secure the cover of housing tightly. Tighten the cable glands.
• For side-mounting, provide a baffle to prevent the application material from falling on the fork.
Please refer to Figure 3.
Figure 3: Correct Side Mounting
• When handling forks, do not lift them using their tines. Please see Figure 4.
• The tines should not be bent and neither should their dimensions be altered. Deforming the shape of the tines may
interfere with the fork’s operating frequency. Please see Figure 4.
• Make all electrical connections as instructed in the manual. Don’t power on the device before verifying the connections.
• To prevent the ingress of moisture and water seepage in side mounting position, the cable entries should always point
downwards.
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User Manual & Datasheet V 2.3
OPEN
ENTER
COVER
UNCOVER
SENSITIVITY
FAILSAFE
VITAL
STATUS
LED
RED
GREEN
LNERelay-1PNP
123456789
++
-
NC CNOOUT
-
AC SupplyDC Supply
L (Live)
N (Neutral)
90-265 V AC18-55 V DC
+
R
L
(Available only in DC Power Supply)
OPEN
ENTER
COVER
UNCOVER
SENSITIVITY
FAILSAFE
VITAL
STATUS
LED
RED
GREEN
LNERelay-1
123456789
+
NC CNO
-
AC SupplyDC Supply
L (Live)
N (Neutral)
90-265 V AC18-55 V DC
+
Relay-2
NCCNO
(a) Fork Handling
(b) Tines Bending
Figure 4: Instrument Handling
• Weatherproofness of enclosure is guaranteed only if the cover is in place glands adequately tightened. Damage due to
accidental entry of water can be avoided if the instrument is installed in a rain shade.
• If the ambient temperature is high, the instrument should not be installed to receive direct sunlight. In case such a position
of shade is not available, a heat shield should be fitted above the instrument especially if the operating temperature lies
between 60◦C and 80◦C.
• While screwing the instrument, the hexagonal mounting bush should be turned and not the housing.
9Electrical Connections
Please refer to Figure 5 for electrical connections.
(a) Electronics option SPDT Relay and
PNP Output(SPN)
Sapcon Instruments Pvt.Ltd.
Figure 5: Electrical Connections
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(b) Electronics option DPDT Relay(D)
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User Manual & Datasheet V 2.3
OPEN
COVER
UNCOVER
SENSITIVITY
FAILSAFE
OPEN
ENTER
COVER
UNCOVER
SENSITIVITY
FAILSAFE
VITAL
STATUS
LED
RED
GREEN
OPEN
ENTER
COVER
UNCOVER
SENSITIVITY
FAILSAFE
VITAL
STATUS
LED
RED
GREEN
OPEN
ENTER
COVER
UNCOVER
SENSITIVITY
FAILSAFE
VITAL
STATUS
LED
RED
GREEN
OPEN
ENTER
COVER
UNCOVER
SENSITIVITY
FAILSAFE
VITAL
STATUS
LED
RED
GREEN
10Sensitivity Settings
The sensitivity settings can be set as per the requirement
using a DIP switch. The value of sensitivity is directly proportional to the number of blinks. 1 blink is the equivalent to
the sensitivity value of 1. Thus, an increase in the number
of blinks will make the instrument more sensitive.
Note:
You can set the value of SENSITIVITY between 1-5.
Follow the below procedure for setting sensitivity
1. Ensure that all DIP switches are in OPEN position as
shown in Figure 6. Make sure that STATUS LED is not
blinking for Error.
Figure 6: DIP Switch
2. To make the instrument sensitive, set the SENSITIVITY switch to CLOSE position as shown in figure 7.
A small screw driver can be used for closing and opening of DIP Switch. (CLOSE is the opposite of OPEN
for a DIP switch). The STATUS RED LED will glow.
4. The value of sensitivity is now entered, but not saved.
To save and test the sensitivity, set the SENSITIVITY
switch back to OPEN position as shown in Figure 9.
The STATUS LED will come back to its original position.
Figure 9: Saving Sensitivity Value
11Cover Delay
When the application material covers the fork tines,
the changeover of the output can be delayed by a predetermined time. This time is called COVER Delay. For
a different value of Cover Delay, the number of blinks can
be adjusted as per requirement.
Note:
You can set the value of COVER DELAY between 125 secs.
Follow the below procedure for setting Cover Delay
1. Ensure that all DIP switches are in OPEN position as
shown in Figure 6. Make sure that STATUS LED is not
blinking for Error.
Figure 7: Sensitivity Switch Position
3. Press ENTER and keep it pressed as shown in Figure
8. The STATUS RED LED starts blinking. Count the
number of blinks. After setting the value release the
ENTER key.
• 5 blinks indicate highest sensitivity which is re-
quired for low density materials.
• 1 blink refers to lowest value of sensitivity which
is required for normal solids.
Sapcon Instruments Pvt.Ltd.
Figure 8: Setting Sensitivity Value
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2. To set the Cover Delay, set the COVER switch to
CLOSE position as shown in Figure 10.
(CLOSE is the opposite of OPEN for a DIP switch.)
The STATUS RED LED will glow.
Figure 10: Cover Delay Switch Position
3. Press ENTER and keep it pressed as shown in Figure
11. The STATUS RED LED will start blinking. Count
the number of blinks. After setting the value release
the ENTER key.
4. Delay is entered, but not saved. To save and test the
Cover Delay, set the COVER switch back to OPEN position as shown in Figure 12. The STATUS LED will
come back to its original position.
5. To test, dip vital into the application material until the
switching point is reached.
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User Manual & Datasheet V 2.3
OPEN
ENTER
COVER
UNCOVER
SENSITIVITY
FAILSAFE
VITAL
STATUS
LED
RED
GREEN
OPEN
ENTER
COVER
UNCOVER
SENSITIVITY
FAILSAFE
VITAL
STATUS
LED
RED
GREEN
OPEN
ENTER
COVER
UNCOVER
SENSITIVITY
FAILSAFE
VITAL
STATUS
LED
RED
GREEN
OPEN
ENTER
COVER
UNCOVER
SENSITIVITY
FAILSAFE
VITAL
STATUS
LED
RED
GREEN
OPEN
ENTER
COVER
UNCOVER
SENSITIVITY
FAILSAFE
VITAL
STATUS
LED
RED
GREEN
OPEN
ENTER
COVER
UNCOVER
SENSITIVITY
FAILSAFE
VITAL
STATUS
LED
RED
GREEN
Figure 11: Setting Cover Delay
Figure 12: Saving Cover Delay
The STATUS LED will start blinking RED if the switch
point is reached. It will blink for the number of seconds for
which the cover delay is set. 1 blink is equal to 1 second
during switching. A maximum of 25 seconds can be set.
12Uncover Delay
When the application material uncovers vital’s fork tines,
the changeover of the output can be delayed by a predetermined time. This time is called UNCOVER Delay. For
a different value of Uncover Delay, the number of blinks can
be adjusted as per requirement.
Figure 14: Setting Uncover Delay
4. Uncover Delay is entered, but not saved. To save and
test the Uncover Delay, set the UNCOVER switch back
to OPEN position as shown in figure 15. The STATUS
LED will come back to its original position.
Figure 15: Saving Uncover Delay
5. To test, dip vital into the application material until the
switching point is achieved.
6. The STATUS LED will start blinking GREEN if the
switch point is achieved. It will blink for the number
of seconds for which the Uncover Delay is set.
Note:
You can set the value of UNCOVER DELAY between
1-25 secs.
Follow the below procedure for setting Uncover
Delay
1. Ensure that all DIP switches are in OPEN position as
shown in Figure 6. Make sure that STATUS LED is not
blinking for Error.
2. To set the Uncover Delay, set the UNCOVER switch to
CLOSE position as shown in Figure 13.
(CLOSE is the opposite of OPEN for a DIP switch.)
The STATUS RED LED will glow.
Figure 13: Uncover Delay Switch Position
3. Press ENTER and keep it pressed as shown in Figure
14. The STATUS RED LED will start blinking. Count
the number of blinks. After setting the value release
the ENTER key.
Sapcon Instruments Pvt.Ltd.
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13Failsafe Settings
In a condition of device failure, known errors and input
power failure the outputs of the device resemble the ALARM
condition. This is meant to prevent overflow or dry run conditions in case of failures.
Prevent Overflow - High Level Switch Failsafe High (default) is set by moving the Failsafe switch to OPEN position.
1. When not in contact with the material, LED turns
GREEN.
2. When in contact with the material, LED turns RED.
Figure 16: Failsafe High
Prevent Dry run - Low Level Switch Failsafe Low is set
by moving the Failsafe switch to CLOSE position
1. When in contact with the material, LED turns GREEN.
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OPEN
ENTER
COVER
UNCOVER
SENSITIVITY
FAILSAFE
VITAL
STATUS
LED
RED
GREEN
Figure 17: Failsafe Low
2. When not in contact with the material, LED turns RED.
User Manual & Datasheet V 2.3
16Customer Support
Thank you for going through the instructions given in this
manual. To further ease the process of installation and use,
we have developed special demo videos which are hosted
on YouTube.
Sapcon’s YouTube channel, SAPCON INSTRUMENTS,
lists all these videos: https://goo.gl/dnxfcz
14Troubleshooting & Indications
14.1
14.2
Output Indications
Green LED Glows When:
• Fork is Uncovered and Failsafe is High
• Fork is Covered and Failsafe is Low
Red LED Glows When:
• Fork is Covered and Failsafe is High
• Fork is Uncovered and Failsafe is Low
Troubleshooting
• The instrument is working but there may be solid par-
ticles in the application material that may be clogging
the fork tines. Make sure particle size is 12 mm.
• Heavy build-up of application material can dampen the
fork oscillations. In this case, the fork requires to be
cleaned. To avoid build up change sensitivity value to
1.
Should you require further information regarding installation, use or working of the instrument, please don’t hesitate
to contact us. Kindly provide the following information at the
time of contacting:
• Instrument Model and Serial Number
• Purchase Order Number and Date of Purchase
• Description of the query
• Your contact details
In an attempt to serve you better, we are open seven days
a week (9:30am to 7:30pm). We are available at:
• www.sapconinstruments.com
• sales@sapcon.in
• +91-731-4757575
• If the vibrating fork is not sensing application media,
consider changing the sensitivity.
• If instrument is not powering on (No LED is glowing).
Check input supply voltage. It should be in the range
mentioned in Electrical Specifications
• Connectivity between Vibating fork and Electron-
ics is broken
– In failsafe ’High’ mode, instrument will switch to
ALARM
– In failsafe ’Low’ mode, instrument will switch to
NORMAL
15Maintenance
The electronics of Vital instrument needs no maintenance. When cleaning and checking the vessel, free the
tuning fork from deposits. If the material has tendency to
form a hard sticky deposit, the instrument must be checked
more often. Make sure that the cable ducts and the lid are
tightly sealed so that no moisture seeps into the instrument.
Sapcon Instruments Pvt.Ltd.
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17Product Selection Order Code
Product
VITAL : Compact Vibrating Fork Type Level Limit Switch for free flowing solids, granules and powders