Operating Instructions - OPTISWITCH 4000 C - with
Contents
1. 3 4 Storage and transport 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 OPTISWITCH 4000 C with transistor output O 8090 NA E9ZLE 31763 EN 060830 The packaging of standard instruments consists of environ ment friendly recyclable cardboard For special versions PE foam or PE foil is also used Dispose of the packaging material via specialised recycling companies Storage and transport tem e Storage and transport temperature see Supplement perature Technical data Ambient conditions e Relative humidity 20 85 OPTISWITCH 4000 C with transistor output 7 Mounting Switching point 4 Mounting 4 1 General instructions In general OPTISWITCH 4000 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 marking notches marking the switching point with vertical mounting The switching point refers to water 1 g cm or 0 036 Ibs in When mounting OPTISWITCH 4000 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 Fig 2 Vertical mounting 1 Switching point approx 13 mm 0 51 in 2 Switching point with lower dens2. 22 Fig 13 Exchange the electronics Fixing screw Valve plug DIN 43650 Profile seal Electronics module Rotary switch 16 steps Plug connector Fixing screw Housing ONDOA UNS 7 4 Instrument repair If a repair is necessary please proceed as follows You can download a return form from our website http www krohne mar com fileadmin media lounge PDF Download OPTISWITCH 4000 C with transistor output O 8090 NA E9ZLE 31763 EN 060830 Specimen e pdf By doing this you help us carry out the repair quickly and without having to call back for needed information e Print and fill out one form per instrument e Clean the instrument and pack it damage proof e Attach the completed form and possibly also a safety data sheet to the instrument OPTISWITCH 4000 C with transistor output 23 Dismounting 24 8 Dismounting 8 1 Dismounting procedure Warning Before dismounting be aware of dangerous process con ditions 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 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 direct
3. 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 4 2 Mounting instructions For welded socket with O ring in front and welding marking OPTISWITCH 4000 C has a defined thread runout point This means that every OPTISWITCH 4000 C is in the same position after being screwed in Remove therefore the supplied flat seal from the thread of OPTISWITCH 4000 C This flat seal is not required when using a welded socket with front flush O ring Before welding unscrew OPTISWITCH 4000 C and remove the rubber ring from the welded socket The welded socket has a marking notch For horizontal mounting weld the socket with the notch facing upward or downward in pipelines aligned with the direction of flow OPTISWITCH 4000 C with transistor output O 8090 NA E9ZLE 31763 EN 060830 Adhesive products Mounting Fig 5 Marking on the welded socket 1 Marking In case of horizontal mounting in adhesive and viscous products the surfaces of the tuning fork should be vertical in order to reduce buildup on the tuning fork The position of the tuning fork is marked by a marking on the hexagon of OPTISWITCH 4000 C 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 suf
4. ce ee 20 7 3 Exchange the electronics 21 7 4 Instrument repair 0 0000 e eee 22 8 Dismounting 8 1 Dismounting procedure 24 82 WISKCsdl csc es nesed eee hes ewe ween 24 9 Supplement 9 1 Technical data 00 0002 eee 25 92 DIMENSIONS c lt 00 2240 BEE RE AS EE We RE 28 OPTISWITCH 4000 C with transistor output O 8090 NA E9ZLE 31763 EN 060830 bm Vv 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 List The dot set in front indicates a list with no implied sequence Action This arrow indicates a single action Sequenc
5. 0 mm protection IP 67 OANDBDAAWBNH OPTISWITCH 4000 C with transistor output 15 Connecting to voltage supply Transistor output 16 d D 3 f a An Fig 9 Connection valve plug DIN 43650 IDC method of termination Compression nut Cable Split taper socket Seal insert Strand Plug housing For connection to binary inputs of a PLC with an input resistance lt 100 kOhm OO0ONROND Max Min 2 3 2 3 PA 10 55V DC PA 10 55V DC Fig 10 Wiring plan Transistor output with valve plug DIN 43650 PA Potential equalisation RL Load resistor contactor relay etc OPTISWITCH 4000 C with transistor output O 8090 NA E9ZLE 31763 EN 060830 KROHNE Connecting to voltage supply GaGa ae 10 55V ne 10 55V i Bas Fig 11 Wiring plan housing Transistor output with M12x1 plug connection 1 Brown 2 White 3 Blue 4 Black RL Load resistor contactor relay etc OPTISWITCH 4000 C with transistor output 17 Set up 18 6 Set up 6 1 Indication of the switching status The switching status of the electronics can be checked on the upper part of the housing 6 2 Function test OPTISWITCH 4000 C has an integrated test switch which can be activated magnetically Proceed as follows to test the instrument gt Hold the test magnet accessory to the magnet symbol on the instrument housing Fig 12 Function tes
6. 04 in gt 0 1 mm gt 0 004 in 1 6 2 0 mm 0 06 0 08 in 5 5 8 0 mm 0 22 0 31 in 10 x to the same cross section OPTISWITCH 4000 C with transistor output O amp 8090 NA E9ZLE 31763 EN 060830 Electrical protective measures Protection Valve plug DIN 43650 Valve plug IDC method of termina tion DIN 43650 M12x1 plug connection Overvoltage category Protection class Approvals Overfill protection acc to WHG OPTISWITCH 4000 C with transistor output Supplement IP 65 IP 67 IP 66 IP 67 IIl II 27 Supplement 9 2 Dimensions OPTISWITCH 4000 C standard version 158mm 6 7 32 165mm 6 1 2 132 5mm 5 7 32 Fig 14 OPTISWITCH 4000 C standard version Thread G34 A G1 A 34 NPT or 1 NPT M12x1 Thread G A G1 A 34 NPT or 1 NPT valve plug DIN 43650 Thread G A G1 A 34 NPT or 1 NPT valve plug DIN 43650 with IDC method of termination Switching point Length with G34 A 34 NPT 66 mm 2 6 in Length with G1 A 1 NPT 69 mm 2 7 in Length with switching point L 48 mm 1 9 in FEE ROND 1 Keep in mind that the total length is extended by the plug connection 28 OPTISWITCH 4000 C with transistor output O 8090 NA E9ZLE 31763 EN 060830 Supplement OPTISWITCH 4000 C high temperature version 42mm i 1 21 32 8mm 188mm 7 13 32 1
7. 82mm 7 11 64 162 5mm 6 25 64 G3 4A 3 4 NPT GTA TNPT Fig 15 OPTISWITCH 4000 C high temperature version Thread G A G1 A 3 NPT or 1 NPT M12x1 Thread G A G1 A NPT or 1 NPT valve plug DIN 43650 Thread G34 A NPT or 1 NPT valve plug DIN 43650 with with IDC method of termination Switching point Length with G34 A 34 NPT 66 mm 2 6 in Length with G1 A 1 NPT 69 mm 2 7 in Length with switching point L 48 mm 1 9 in FEE KON 2 Keep in mind that the total length is extended by the plug connection OPTISWITCH 4000 C with transistor output 29 Supplement 30 OPTISWITCH 4000 C with transistor output O 8090 NA E9ZLE 31763 EN 060830 OPTISWITCH 4000 C with transistor output Supplement 31 Subject to change without notice 31763 EN 060830
8. Operating Instructions OPTISWITCH 4000 C with transistor output Variable area flowmeters Vortex flowmeters Flow controllers Electromagnetic flowmeters Ultrasonic flowmeters Mass flowmeters Level measuring instruments Communications engineering Engineering systems amp solutions Switches counters displays and recorders Heat metering Pressure and temperature Contents Contents 1 About this document EN AT OE OE E tose 3 1 2 Target groUP sure boca Se coheed end BEE 3 13 Symbolism used 00000 eee 3 2 For your safety 2 1 Authorised personnel 00 4 2 2 Appropriate use 2 0 0 0 ee ee 4 2 3 Warning about misuse 4 24 CE COMOMINY iss ses oe HER SERE He RE 4 3 Product description 3 1 Configuration 2 0 SS SS ee ee 5 3 2 Principle of operation 00 5 SO Ope ie s xe oh OE N EEN 6 34 Storage and transport ESE ss ee 6 4 Mounting 4 1 General instructions 08 8 4 2 Mounting instructions 5 10 5 Connecting to voltage supply 5 1 Preparing the connection 13 5 2 Wiring Plan so MERE goed eee sew ee eens 14 6 Set up 6 1 Indication of the switching status 18 6 2 Functiontest 0 000 cece ee 18 6 3 Function chart nasao aaa 00 000 e ee eee 19 7 Maintenance and fault rectification 7 1 Maintenance 0 0 00 eee 20 7 2 Rectify faults 0 0 0 0
9. Tri Clamp 1 Tri Clamp 1 bolting DN 25 PN 40 bolting DN 40 PN 40 SMS Ra lt 3 2 um 1 26 in Ra 0 8 um 3 157 in approx 2 mm 0 08 in with vertical installation approx 500 ms approx 1200 Hz 40 70 C 40 158 F 40 80 C 40 176 F 1 64 bar 14 5 938 psi 40 100 C 40 212 F 40 150 C 40 302 F no limitation 0 1 10000 mPa s 0 7 2 5 g cm 0 025 0 9 oz in 25 Supplement Operation Plug connections Signal lamp LED Green red Red flashing Output variable Output Load current Voltage loss Turn on voltage Blocking current Mode min max max min Voltage supply Supply voltage Power consumption Electromechanical data Valve plug DIN 43650 wire cross section Cable outer diameter Specification see Connecting to power supply Output conductive Output blocked Failure Output blocked Transistor output PNP max 250 mA output overload and perma nently shortcircuit proof max 1 V max 55 V DC lt 10 HA Changeover by electronic connection Overfill protection Dry run protection 10 55V DC max 0 5 W 1 5 mm 0 06 in 4 5 7 0 mm 0 18 0 28 in Valve plug DIN 43650 IDC method of termination 26 wire cross section Single wire diameter Wire diameter Cable outer diameter Connection frequency for wire cross section of 0 5 1 0 mm 0 02 0
10. e Numbers set in front indicate successive steps in a procedure OPTISWITCH 4000 C with transistor output 3 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 4000 C is a sensor for level detection Detailed information on the application range of OPTISWITCH 4000 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 4000 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 4000 C is in CE conformity with EMC 89 336 EWG fulfils Namur recommendation NE 21 and NE 23 and is in CE conformity with NSR 73 23 EWG Conformity has bee
11. ficient to reach the recommended installation position In adhesive and viscous products the surfaces of the tuning fork should protrude into the vessel to avoid buildup Therefore sockets for flanges and mountings bosses should not exceed a certain length Fig 6 Adhesive products OPTISWITCH 4000 C with transistor output 11 Mounting Inflowing medium Flows 12 If OPTISWITCH 4000 C is mounted in the filling stream unwanted switching signals may be generated Mount OPTI SWITCH 4000 C at a location in the vessel where no disturbing influence from e g filling openings agitators etc can occur To minimise flow resistance caused by the tuning fork OPTISWITCH 4000 C should be mounted in such a way that the surfaces of the blades are parallel to the product movement OPTISWITCH 4000 C with transistor output O 8090 NA E9ZLE 31763 EN 060830 Note safety instructions Selecting the connection ca ble Cable glands Connecting to voltage supply 5 Connecting to voltage supply 5 1 Preparing the connection Generally not the following safety instructions e Connect only in the complete absence of line voltage OPTISWITCH 4000 C is connected with standard cable with round cross section Depending on the plug connection you have to select the outer diameter of the cable respectively so that the seal effect of the cable gland is ensured e Valve plug DIN 43650 4 5 7 mm e Valve plug IDC me
12. h as turbulence air bubbles foam generation buildup strong external vibration or changing products Fault monitoring The electronics module of OPTISWITCH 4000 C continuously monitors via frequency evaluation the following criteria e Strong corrosion or damage on the tuning fork e loss of vibration e Line break to the piezo drive If a malfunction is detected or in case of power failure the electronics takes on a defined switching condition i e the output transistor blocks safe condition The tuning fork is piezoelectrically energised and vibrates at its mechanical resonance frequency of approx 1200 Hz The piezos are fixed mechanically and are hence not subject to temperature shock limitations The frequency changes when the tuning fork is covered by the medium This change is detected by the integrated oscillator and converted into a switching command OPTISWITCH 4000 C is a compact instrument i e it can be operated without external evaluation system The integrated electronics evaluates the level signal and outputs a switching signal With this switching signal a connected device can be directly activated e g a warning system a PLC a pump etc The exact range of the power supply is stated in the Technical data in the Supplement 3 3 Operation The switching status of OPTISWITCH 4000 C can be checked with closed housing signal lamp Products with a density gt 0 7 g cm gt 0 025 Ibs in can be detected
13. ity 3 Switching point with higher density OPTISWITCH 4000 C with transistor output O 8090 NA E9ZLE 31763 EN 060830 Moisture Transport Mounting Fig 3 Horizontal mounting 1 Switching point 2 Switching point recommended mounting position particularly for adhesive products Use the recommended cables see chapter Connecting to power supply and tighten the cable gland You can give your OPTISWITCH 4000 C additional protection against moisture penetration by leading the connection cable downward in front of the cable entry Rain and condensation water can thus drain off This applies mainly to mounting outdoors in areas where moisture is expected e g by cleaning processes or on cooled or heated vessels Fig 4 Measures against moisture penetration Do not hold OPTISWITCH 4000 C on the tuning fork OPTISWITCH 4000 C with transistor output 9 Mounting Pressure Vacuum Handling Welded socket 10 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
14. ive 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 OPTISWITCH 4000 C with transistor output O 8090 NA E9ZLE 31763 EN 060830 9 Supplement 9 1 Technical data General data Supplement Material 316L corresponds to 1 4404 or 1 4435 Materials wetted parts Tuning fork Process seal Process fittings Materials non wetted parts Housing Weight Process fittings Thread hygienic fittings Surface quality Standard hygienic version Measuring accuracy Hysteresis Integration time Frequency Ambient conditions Ambient temperature on the housing Storage and transport temperature Process conditions Process pressure Process temperature Standard Process temperature High temper ature version option Temperature shock Viscosity dynamic Density OPTISWITCH 4000 C with transistor output 316L Klingersil C 4400 316L 316L and plastic PEI approx 250 g ca 9 oz G A G1 A NPT or 1 NPT
15. n judged according to the following standards e EMC Emission EN 61326 1997 class B Susceptibility EN 61326 1997 A1 1998 e LVD EN 61010 1 2001 OPTISWITCH 4000 C with transistor output O amp 8090 NA E9ZLE 31763 EN 060830 Scope of delivery Components Area of application Product description 3 Product description 3 1 Configuration The scope of delivery encompasses e OPTISWITCH 4000 C level sensor e Test magnet e Documentation this operating instructions manual if necessary certificates OPTISWITCH 4000 C consists of the following components e Housing with electronics e process fitting with tuning fork Fig 1 OPTISWITCH 4000 C 3 2 Principle of operation OPTISWITCH 4000 C is a level sensor with tuning fork for level detection 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 4000 C can be also mounted e g in pipelines from DN 25 The small tuning OPTISWITCH 4000 C with transistor output 5 Product description Physical principle Power supply Packaging fork allows use in vessels tanks and pipes Thanks to its simple and robust measuring system OPTISWITCH 4000 C is virtually unaffected by the chemical and physical properties of the liquid It functions even under difficult conditions suc
16. s can occur during operation These may be caused by the following e g Sensor Process Power supply 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 Control lamps off Voltage supply interrupted gt Check the voltage supply and the cable connection gt Exchange the electronics module Signal lamp flashes red There was no load connected when connecting to power supply gt Connect the instrument correctly gt Check if the tuning fork is damage or extremely corroded Frequency error gt Adjust the instrument correctly The signal lamp flashes alternately red and green Shortcircuit or overload gt Check the electrical connection OPTISWITCH 4000 C with transistor output O amp 8090 NA E9ZLE 31763 EN 060830 Maintenance and fault rectification 7 3 Exchange the electronics To exchange the electronics in case of failure it is not necessary to dismount the instrument Dismounting the electronics module can destroy the housing seal Therefore only open the instrument if you want to inserta new electronics module The housing seal is supplied with the electronics module You require an electronics module type SWESOT or SWES50C If you want to use an electronics module with another signal output e g contactless electronic switch SWE50C you can download the suitable operating instruc
17. t The test magnet changes the current switching condition of the instrument You can check the change on the signal lamp Please note that the connected instruments are activated during the test If OPTISWITCH 4000 C does not switch over after several tests with the test magnet you have to check the plug connection and the connection cable and test the instrument again If there is no switching function the electronics will be defective In this case you have to exchange the electronics or return the instrument to our repair department Caution OPTISWITCH 4000 C with transistor output O 8090 NA E9ZLE 31763 EN 060830 Set up It is absolutely necessary that you remove the test magnet after the test from the instrument housing 6 3 Function chart The following chart provides an overview of the switching conditions depending on the adjusted mode and level Mode max ay transistor conducts Mode max transistor blocks transistor conducts Mode min transistor blocks transistor blocks flashes red OPTISWITCH 4000 C with transistor output 19 Maintenance and fault rectification Causes of malfunction Fault rectification Checking the switching signal 20 7 Maintenance and fault rectification 7 1 Maintenance When used as directed in normal operation OPTISWITCH 4000 C is completely maintenance free 7 2 Rectify faults OPTISWITCH 4000 C offers maximum reliability Nevertheless fault
18. thod of termination DIN 43650 5 5 8 0 mm Use cable with a round wire cross section and tighten the cable gland When mounting outdoors on cooled vessels or in humid areas in which cleaning is carried out e g with steam or high pressure it is particularly important to seal the cable gland OPTISWITCH 4000 C with transistor output 13 Connecting to voltage supply Housing overview Plug versions 14 5 2 Wiring plan Fig 7 Overview of the connection versions 1 M12x1 plug connection 2 Valve plug DIN 43650 3 Valve plug DIN 43650 with IDC method of termination M12x1 plug connection This plug connection requires a preconfectioned cable with plug Protection IP 66 IP 67 Valve plug DIN 43650 For this plug version standard cable with round wire cross section can be used Cable diameter 4 5 7 mm protection IP 65 OPTISWITCH 4000 C with transistor output O 8090 NA E9ZLE 31763 EN 060830 Connecting to voltage supply Ma Fig 8 Connection valve plug DIN 43650 Pressure screw Pressure disk Seal ring Fixing screw Seal washer Plug housing Plug insert Profile seal Control lamp 10 OPTISWITCH 4000 C Valve plug DIN 43650 IDC method of termination For this plug version you can use standard cable with round wire cross section The inner cables must not be dismantled The plug connects the cables automatically when screwing them in Cable diameter 5 5 8
19. tions manual from our homepage under Downloads Take note of the specifications in the respective operating instructions manual To exchange the electronics module proceed as follows Separate OPTISWITCH 4000 C from operating voltage 2 Loosen screw 1 of the valve plug 2 with a wrench loosen M12x1 plug connection by turning the compression nut Remove valve plug 2 or M12x1 acc to drawing Remove lateral fixing screw 7 with a crosstip screwdriver Pull electronics module 4 carefully out of the housing 8 O oo A O Remove the plug of the connection cable 6 from the socket on the oscillator 4 7 Set the 16 step rotating switch 5 of the new replacement electronics module 4 to the value of the defective electronics module 8 Insert the connection cable 6 in the socket of the new electronics module 4 9 Insert electronics module 4 into the housing 8 Make sure that the lateral thread on the electronics module is above the hole on the housing 8 10 Push the electronics module 4 flush into the housing 8 11 Screw in the lateral fixing screw 7 with a crosstip screwdriver 12 Plug the valve plug 2 to the instrument make sure that the profile seal 3 is placed correctly 13 Tighten the screw 1 with a wrench fasten M12x1 plug connection by screwing the compression nut OPTISWITCH 4000 C is again ready for operation OPTISWITCH 4000 C with transistor output 21 Maintenance and fault rectification
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