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7 Maintenance and fault rectification

OPTISWITCH 5100 C, 5150 C • Contactless electronic switch

30428-EN-210701

Note:

Keep in mind that enamelled instrument versions need special

electronics modules. These electronics modules are called SW60E or

SW60E1.

7.4 How to proceed if a repair is necessary

If it is necessary to repair the instrument, please contact the responsi-

ble Krohne agency.

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Summary of Contents for OPTISWITCH 5100 C

Page 1: ...OPTISWITCH 5100 C 5150 C Handbook Vibrating Level Switch Contactless electronic switch ...

Page 2: ...n 7 3 1 Configuration 7 3 2 Principle of operation 7 3 3 Adjustment 8 3 4 Storage and transport 9 3 5 Accessories 9 4 Mounting 11 4 1 General instructions 11 4 2 Mounting instructions 14 5 Connecting to power supply 16 5 1 Preparing the connection 16 5 2 Connection procedure 17 5 3 Wiring plan single chamber housing 17 6 Setup 20 6 1 General information 20 6 2 Adjustment elements 20 6 3 Function t...

Page 3: ...3 Contents OPTISWITCH 5100 C 5150 C Contactless electronic switch 30428 EN 210701 Editing status 2019 11 21 ...

Page 4: ... Symbols used Information note tip This symbol indicates helpful additional infor mation and tips for successful work Note This symbol indicates notes to prevent failures malfunctions damage to devices or plants Caution Non observance of the information marked with this symbol may result in personal injury Warning Non observance of the information marked with this symbol may result in serious or f...

Page 5: ...l overfill through incorrect mounting or adjustment Damage to property and persons or environmental contamination can result Also the protective characteristics of the instrument can be impaired 2 4 General safety instructions This is a state of the art instrument complying with all prevailing regulations and directives The instrument must only be operated in a technically flawless and reliable co...

Page 6: ... resp IEC 61511 You can find further information in the Safety Manual OPTISWITCH 5XXX 2 8 Installation and operation in the USA and Canada This information is only valid for USA and Canada Hence the follow ing text is only available in the English language Installations in the US shall comply with the relevant requirements of the National Electrical Code ANSI NFPA 70 Installations in Canada shall ...

Page 7: ...uning fork 1 2 3 Fig 1 OPTISWITCH 5100 C 5150 C 1 Housing lid 2 Housing with electronics 3 Process fitting The type label contains the most important data for identification and use of the instrument Article number Serial number Technical data Article numbers documentation SIL identification with SIL rating ex works In addition to the type label outside on the instrument you find the serial number...

Page 8: ...d vibrates at its mechanical resonance frequency of approx 1200 Hz The piezos are fixed mechanically and are hence not subject to temperature shock limitations The frequency changes when the tuning fork is covered by the medium This change is detected by the integrated electronics module and converted into a switching command OPTISWITCH 5100 C 5150 C is a compact instrument i e it can be operated ...

Page 9: ...orientation and storage markings on the outside Unless otherwise indicated the packages must be stored only under the following conditions Not in the open Dry and dust free Not exposed to corrosive media Protected against solar radiation Avoiding mechanical shock and vibration Storage and transport temperature see chapter Supplement Technical data Ambient conditions Relative humidity 20 85 With in...

Page 10: ...10 3 Product description OPTISWITCH 5100 C 5150 C Contactless electronic switch 30428 EN 210701 ISO 4400 Harting HAN 7D Harting HAN 8D Amphenol Tuchel ...

Page 11: ... as well as outdoors In general OPTISWITCH 5100 C 5150 C can be installed in any position The instrument only has to be mounted in such a way that the tuning fork is at the height of the desired switching point The tuning fork has lateral markings notches that indicate the switching point with vertical mounting The switching point applies to water in conjunction with the basic setting of the densi...

Page 12: ...sity 3 Switching point with higher density 4 Switching point approx 27 mm 1 06 in 2 1 Fig 3 Horizontal mounting 1 Switching point 2 Marking with screwed version facing up 1 2 Fig 4 Horizontal installation recommended mounting position particularly for adhesive products 1 Switching point 2 Marking with screwed version facing up In the case of flange versions the fork is aligned as follows ...

Page 13: ... g through cleaning processes or on cooled or heated vessels To maintain the housing protection make sure that the housing lid is closed during operation and locked if necessary Fig 6 Measures against moisture ingress Caution Do not hold OPTISWITCH 5100 C 5150 C on the tuning fork Particu larly with flange or tube versions the tuning fork can be damaged just by the weight of the instrument Transpo...

Page 14: ...ds are therefore covered with red dust protection caps as transport protection Prior to setup you have to replace these protective caps with ap proved cable glands or close the openings with suitable blind plugs 4 2 Mounting instructions OPTISWITCH 5100 C 5150 C has a defined thread starting point This means that every OPTISWITCH 5100 C 5150 C is in the same fork position after being screwed in Re...

Page 15: ...ges and mounting bosses should be avoided when mounting horizontally If OPTISWITCH 5100 C 5150 C is mounted in the filling stream un wanted false measurement signals can be generated For this reason mount OPTISWITCH 5100 C 5150 C at a position in the vessel where no disturbances e g from filling openings agitators etc can occur To make sure the tuning fork of OPTISWITCH 5100 C 5150 C gener ates as...

Page 16: ...the inner earth conductor terminal Keep the general installation regulations in mind Take note of the corresponding installation regulations for hazardous areas with Ex applications The data for power supply are specified in chapter Technical data The instrument is connected with standard three wire cable without screen If electromagnetic interference is expected which is above the test values of ...

Page 17: ...crewdriver 6 Insert the wire ends into the open terminals according to the wir ing 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 gland The seal ring must completely encircle the cable 10 Screw the housing lid back on The electrical connection is finished 5 3 Wiring plan sing...

Page 18: ...ctless electronic switch is always shown in non operative condition Warning The instrument must not be operated without an intermediately connected load because the electronics would be destroyed if con nected directly to the mains It is not suitable for connection to low voltage PLC inputs Examples for typical applications Load resistance at 24 V DC 88 1800 Ω Rated power relay 253 V AC 2 5 VA Rat...

Page 19: ... C Contactless electronic switch 30428 EN 210701 When OPTISWITCH 5100 C 5150 C is used as part of an overfill protection system according to WHG also note the regulations of the general type approval 1 2 AC DC L1 N Fig 10 Wiring plan single chamber housing ...

Page 20: ...p 1 DIL switch for mode adjustment A B 2 DIL switch for adjustment of the density range 3 Note Always immerse the tuning fork of OPTISWITCH 5100 C 5150 C in a liquid to test its function Do not test the function of OPTISWITCH 5100 C 5150 C with your hand This can damage the sensor 6 2 Adjustment elements 1 2 1 2 3 Fig 11 Oscillator SWE60C Contactless electronic switch 1 Control lamp LED 2 DIL swit...

Page 21: ... 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 Note Keep in mind that foams with a density 0 45 g cm 0 016 lbs in are detected by the sensor This can lead to erroneous switchings particulary when the sensor is used for dry run protection 6 3 Function table The following table provides an overvie...

Page 22: ...22 6 Setup OPTISWITCH 5100 C 5150 C Contactless electronic switch 30428 EN 210701 Level Switching status Control lamp Fault any 2 1 Switch open flashes red ...

Page 23: ...gs type label and seals Use only cleaning methods corresponding to the housing protec tion rating 7 2 Rectify faults The operator of the system is responsible for taking suitable meas ures to rectify faults The device offers maximum reliability Nevertheless faults can occur during operation These may be caused by the following e g Sensor Process Voltage supply Signal processing The first measure t...

Page 24: ... selected Set the correct mode with the mode switch overflow protection dry run protection Wiring should be carried out according to the closed circuit principle Signal lamp flashes red Error on the vibrating element Check if the vibrating element is damaged or extremely corroded Interference on the electronics mod ule Exchanging the electronics module instrument defective Exchange the instrument ...

Page 25: ...itch 30428 EN 210701 Note Keep in mind that enamelled instrument versions need special electronics modules These electronics modules are called SW60E or SW60E1 7 4 How to proceed if a repair is necessary If it is necessary to repair the instrument please contact the responsi ble Krohne agency ...

Page 26: ...peratures corrosive or toxic products etc Take note of chapters Mounting and Connecting to voltage 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 device is made of recyclable materials For this reason it should be disposed of by a specialist recycling company Observe the ap...

Page 27: ...th ECTFE coating 316L with PFA coating Sensor length Ʋ Ʋ Length OPTISWITCH 5100 C 5150 C See chapter Supplement Dimensions Materials non wetted parts Ʋ Ʋ Plastic housing Plastic PBT Polyester Ʋ Ʋ Aluminium die cast housing Aluminium die casting AlSi10Mg powder coated Basis Polyester Ʋ Ʋ Stainless steel housing precision casting 316L Ʋ Ʋ Stainless steel housing electropol ished 316L Ʋ Ʋ Seal betwee...

Page 28: ... from DN 25 ASME from 1 Ʋ Ʋ hygienic fittings Slotted nut DN 40 PN 40 Clamp 1 DIN 32676 ISO 2852 316L Clamp 2 DIN 32676 ISO 2852 316L conus DN 25 PN 40 Tuchenhagen Varivent DN 50 PN 10 Max torque process fitting Ʋ Ʋ Thread G NPT 75 Nm 55 lbf ft Ʋ Ʋ Thread G1 1 NPT 100 Nm 73 lbf ft Torque for NPT cable glands and Conduit tubes Ʋ Ʋ Plastic housing max 10 Nm 7 376 lbf ft Ʋ Ʋ Aluminium Stainless steel...

Page 29: ... Vertically from top Ʋ Ʋ Density selection switch 0 7 g cm Measurement accuracy Deviation 1 mm 0 04 in Influence of the process temperature on the switching point 1 3 4 2 10 25 64 8 5 16 6 15 64 4 5 32 2 5 64 2 5 64 4 5 32 6 15 64 8 5 16 10 25 64 0 0 C 32 F 100 C 212 F 150 C 302 F 200 C 392 F 250 C 482 F 50 C 122 F Fig 12 Influence of the process temperature on the switching point 1 Shifting of th...

Page 30: ...sition 0 5 g cm 0 018 lb in 4 Switch position 0 7 g cm 0 025 lb in 5 Switching point at reference conditions notch 6 Tuning fork Influence of the process pressure to the switching point 1 2 3 4 12 174 1 38 551 1 25 362 6 51 739 7 64 928 2 10 25 64 8 5 16 6 15 64 4 5 32 2 5 64 2 5 64 4 5 32 6 15 64 8 5 16 10 25 64 0 Fig 14 Influence of the process pressure to the switching point 1 Shifting of the s...

Page 31: ...ing pressure of 100 bar 10000 kPa 1450 psig at a maximum process temperature of 50 C 122 F only with threaded versions Process temperature thread or flange temperature Ʋ Ʋ OPTISWITCH 5100 C 5150 C of 316L Alloy C22 2 4602 50 150 C 58 302 F Process temperature thread or flange temperature with temperature adapter option Ʋ Ʋ OPTISWITCH 5100 C 5150 C of 316L Alloy C22 2 4602 50 250 C 58 482 F Ʋ Ʋ OPT...

Page 32: ...h switch position 0 5 g cm sensitivity switch 1 Process pressure in bar psig 2 Process temperature in C F SIP process temperature SIP Sterilization in place PFA and ECTFE coatings are not suitable for SIP cleaning Vapour stratification up to 2 h 150 C 302 F Additional process conditions Viscosity dynamic 0 1 10000 mPa s requirement with density 1 Flow velocity max 6 m s with a viscosity of 10000 m...

Page 33: ... g cm 0 025 0 09 lbs in Voltage supply Operating voltage 20 253 V AC 50 60 Hz 20 253 V DC Domestic current requirement approximately 3 mA via load circuit Load current Ʋ Ʋ Min 10 mA Ʋ Ʋ Max 400 mA with I 300 mA the ambient temperature can be max 60 C 140 F max 4 A up to 40 ms not WHG specified Electrical protective measures Protection rating IP66 IP67 acc to IEC 60529 Type 4X acc to NEMA Altitude ...

Page 34: ... mm 2 72 ø 77 mm 3 03 117 mm 4 61 M20x1 5 NPT 59 mm 2 32 ø 80 mm 3 15 112 mm 4 41 M20x1 5 NPT 69 mm 2 72 ø 77 mm 3 03 112 mm 4 41 M20x1 5 NPT 116 mm 4 57 ø 84 mm 3 31 114 mm 4 49 M20x1 5 M20x1 5 NPT Fig 18 Housing versions 1 Plastic housing 2 Stainless steel housing electropolished 3 Stainless steel housing precision casting 4 Aluminium housing ...

Page 35: ...A 1 NPT 18 5 mm 0 73 32 G A NPT 41 G1A 1 NPT 57 mm 2 24 50 mm 1 97 ø 33 7 mm 1 33 36 mm 1 42 19 mm 0 75 49 mm 1 93 50 mm 1 97 53 mm 2 09 53 mm 2 09 53 mm 2 09 55 mm 2 17 G 66 mm 2 6 G1 69 mm 2 72 4 5 6 6 1 2 3 Fig 19 OPTISWITCH 5100 C 5150 C 1 Thread 2 Clamp 3 Cone DN 25 4 Slotted nut DN 40 5 Flange 6 Tuchenhagen Varivent ...

Page 36: ...9 Supplement OPTISWITCH 5100 C 5150 C Contactless electronic switch 30428 EN 210701 OPTISWITCH 5100 C 5150 C options 38 mm 1 50 178 mm 7 01 1 2 Fig 20 Options 1 Gas tight leadthrough 2 Temperature adapter ...

Page 37: ... 9 Supplement OPTISWITCH 5100 C 5150 C Contactless electronic switch 30428 EN 210701 9 3 Trademark All the brands as well as trade and company names used are property of their lawful proprietor originator ...

Page 38: ...38 Notes OPTISWITCH 5100 C 5150 C Contactless electronic switch 30428 EN 210701 ...

Page 39: ...39 Notes OPTISWITCH 5100 C 5150 C Contactless electronic switch 30428 EN 210701 ...

Page 40: ... process analytics Flow metering monitoring wireless and remote metering solu tions Engineering commissioning calibration maintenance and train ing services Head Office KROHNE Messtechnick GmbH Ludwig Krohne Straße 5 47058 Duisburg Germany Tel 49 0 203 301 0 Tel 49 0 203 301 10389 info krohne de The current list of all KROHNE contacts and addresses can be found at www krohne com ...

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