KROHNE OPTIFLUX 4000 User manual

Electromagnetic flow sensor
OPTIFLUX 4000
OPTIFLUX 4000OPTIFLUX 4000
OPTIFLUX 4000 Handbook
HandbookHandbook
Handbook
© KROHNE 08/2017 - 4000818505 - HB OPTIFLUX 4000 R05 en
The documentation is only complete when used in combination with the relevant
documentation for the signal converter.

All rights reserved. It is prohibited to reproduce this documentation, or any part thereof, without
the prior written authorisation of KROHNE Messtechnik GmbH.
Subject to change without notice.
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Copyright 2017 by
KROHNE Messtechnik GmbH - Ludwig-Krohne-Str. 5 - 47058 Duisburg (Germany)
:IMPRINT :::::::::::::::::::::::::::::::::::::::

CONTENTS
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OPTIFLUX 4000
1 Safety instructions 5
1.1 Intended use ..................................................................................................................... 5
1.2 Certification ...................................................................................................................... 5
1.3 Safety instructions from the manufacturer ..................................................................... 6
1.3.1 Copyright and data protection ................................................................................................ 6
1.3.2 Disclaimer ............................................................................................................................... 6
1.3.3 Product liability and warranty ................................................................................................ 7
1.3.4 Information concerning the documentation........................................................................... 7
1.3.5 Warnings and symbols used................................................................................................... 8
1.4 Safety instructions for the operator................................................................................. 8
2 Device description 9
2.1 Scope of delivery............................................................................................................... 9
2.2 Device description .......................................................................................................... 10
2.3 Nameplate ...................................................................................................................... 11
3 Installation 12
3.1 General notes on installation ......................................................................................... 12
3.2 Storage ........................................................................................................................... 12
3.3 Transport ........................................................................................................................ 12
3.4 Pre-installation requirements ....................................................................................... 13
3.5 General requirements.................................................................................................... 13
3.5.1 Vibration ................................................................................................................................ 13
3.5.2 Magnetic field........................................................................................................................ 13
3.6 Installation conditions ....................................................................................................14
3.6.1 Inlet and outlet ...................................................................................................................... 14
3.6.2 Bends in 2 or 3 dimensions................................................................................................... 14
3.6.3 T-section ............................................................................................................................... 15
3.6.4 Bends .................................................................................................................................... 15
3.6.5 Open feed or discharge......................................................................................................... 16
3.6.6 Flange deviation.................................................................................................................... 16
3.6.7 Control valve ......................................................................................................................... 16
3.6.8 Pump ..................................................................................................................................... 17
3.6.9 Air venting and vacuum forces ............................................................................................. 17
3.6.10 Mounting position................................................................................................................ 18
3.7 Mounting......................................................................................................................... 19
3.7.1 Torques and pressures......................................................................................................... 19
3.8 Temperatures ................................................................................................................. 22
4 Electrical connections 23
4.1 Safety instructions.......................................................................................................... 23
4.2 Grounding ....................................................................................................................... 23
4.3 Virtual reference for IFC 300 (C, W and F version) ....................................................... 25
4.4 Connection diagrams ..................................................................................................... 25

CONTENTS
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OPTIFLUX 4000
5 Service 26
5.1 Spare parts availability...................................................................................................26
5.2 Availability of services .................................................................................................... 26
5.3 Returning the device to the manufacturer..................................................................... 26
5.3.1 General information.............................................................................................................. 26
5.3.2 Form (for copying) to accompany a returned device............................................................ 27
5.4 Disposal .......................................................................................................................... 27
6 Technical data 28
6.1 Measuring principle........................................................................................................28
6.2 Technical data................................................................................................................. 29
6.3 Legal metrology.............................................................................................................. 37
6.3.1 OIML R49 ............................................................................................................................... 37
6.3.2 MID Annex III (MI-001)........................................................................................................... 39
6.3.3 Verification to MI-001 & OIML 49.......................................................................................... 41
6.3.4 OIML R117 ............................................................................................................................. 42
6.3.5 MI-005 ................................................................................................................................... 42
6.4 Measurement accuracy.................................................................................................. 43
6.5 Dimensions and weights ................................................................................................ 45
6.6 Pressure derating........................................................................................................... 50
6.7 Vacuum load ................................................................................................................... 52
7 Notes 53

SAFETY INSTRUCTIONS 1
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1.1 Intended use
The measurement of volumetric flowrate of electrically conductive fluids. Basic measurement is
the flow velocity upon which all other measurements are based.
1.2 Certification
This device fulfils the statutory requirements of the relevant EU directives.
For full information of the EU directives and standards and the approved certifications, please
refer to the (8'HFODUDWLRQRI&RQIRUPLW\ or the website of the manufacturer.
Other approvals and standards
•Measuring Instruments Directive 2014/32/EU - , Annex III (MI-001), Annex VII (MI-005)
For more information, please refer to the dedicated documentation.
CAUTION!
Responsibility for the use of the measuring devices with regard to suitability, intended use and
corrosion resistance of the used materials against the measured fluid lies solely with the
operator.
INFORMATION!
The manufacturer is not liable for any damage resulting from improper use or use for other than
the intended purpose.
CE marking
The manufacturer certifies successful testing of the product by applying the CE marking.
DANGER!
For devices used in hazardous areas, additional safety notes apply. Please refer to the Ex
documentation.

1SAFETY INSTRUCTIONS
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1.3 Safety instructions from the manufacturer
1.3.1 Copyright and data protection
The contents of this document have been created with great care. Nevertheless, we provide no
guarantee that the contents are correct, complete or up-to-date.
The contents and works in this document are subject to copyright. Contributions from third
parties are identified as such. Reproduction, processing, dissemination and any type of use
beyond what is permitted under copyright requires written authorisation from the respective
author and/or the manufacturer.
The manufacturer tries always to observe the copyrights of others, and to draw on works created
in-house or works in the public domain.
The collection of personal data (such as names, street addresses or e-mail addresses) in the
manufacturer's documents is always on a voluntary basis whenever possible. Whenever
feasible, it is always possible to make use of the offerings and services without providing any
personal data.
We draw your attention to the fact that data transmission over the Internet (e.g. when
communicating by e-mail) may involve gaps in security. It is not possible to protect such data
completely against access by third parties.
We hereby expressly prohibit the use of the contact data published as part of our duty to publish
an imprint for the purpose of sending us any advertising or informational materials that we have
not expressly requested.
1.3.2 Disclaimer
The manufacturer will not be liable for any damage of any kind by using its product, including,
but not limited to direct, indirect or incidental and consequential damages.
This disclaimer does not apply in case the manufacturer has acted on purpose or with gross
negligence. In the event any applicable law does not allow such limitations on implied warranties
or the exclusion of limitation of certain damages, you may, if such law applies to you, not be
subject to some or all of the above disclaimer, exclusions or limitations.
Any product purchased from the manufacturer is warranted in accordance with the relevant
product documentation and our Terms and Conditions of Sale.
The manufacturer reserves the right to alter the content of its documents, including this
disclaimer in any way, at any time, for any reason, without prior notification, and will not be liable
in any way for possible consequences of such changes.

SAFETY INSTRUCTIONS 1
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1.3.3 Product liability and warranty
The operator shall bear responsibility for the suitability of the device for the specific purpose.
The manufacturer accepts no liability for the consequences of misuse by the operator. Improper
installation or operation of the devices (systems) will cause the warranty to be void. The
respective "Standard Terms and Conditions" which form the basis for the sales contract shall
also apply.
1.3.4 Information concerning the documentation
To prevent any injury to the user or damage to the device it is essential that you read the
information in this document and observe applicable national standards, safety requirements
and accident prevention regulations.
If this document is not in your native language and if you have any problems understanding the
text, we advise you to contact your local office for assistance. The manufacturer can not accept
responsibility for any damage or injury caused by misunderstanding of the information in this
document.
This document is provided to help you establish operating conditions, which will permit safe and
efficient use of this device. Special considerations and precautions are also described in the
document, which appear in the form of icons as shown below.

1SAFETY INSTRUCTIONS
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1.3.5 Warnings and symbols used
Safety warnings are indicated by the following symbols.
• HANDLING
HANDLINGHANDLING
HANDLING
This symbol designates all instructions for actions to be carried out by the operator in the
specified sequence.
i RESULT
RESULTRESULT
RESULT
This symbol refers to all important consequences of the previous actions.
1.4 Safety instructions for the operator
DANGER!
This warning refers to the immediate danger when working with electricity.
DANGER!
This warning refers to the immediate danger of burns caused by heat or hot surfaces.
DANGER!
This warning refers to the immediate danger when using this device in a hazardous atmosphere.
DANGER!
These warnings must be observed without fail. Even partial disregard of this warning can lead to
serious health problems and even death. There is also the risk of seriously damaging the device
or parts of the operator's plant.
WARNING!
Disregarding this safety warning, even if only in part, poses the risk of serious health problems.
There is also the risk of damaging the device or parts of the operator's plant.
CAUTION!
Disregarding these instructions can result in damage to the device or to parts of the operator's
plant.
INFORMATION!
These instructions contain important information for the handling of the device.
LEGAL NOTICE!
This note contains information on statutory directives and standards.
WARNING!
In general, devices from the manufacturer may only be installed, commissioned, operated and
maintained by properly trained and authorized personnel.
This document is provided to help you establish operating conditions, which will permit safe and
efficient use of this device.

DEVICE DESCRIPTION 2
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2.1 Scope of delivery
INFORMATION!
Do a check of the packing list to make sure that you have all the elements given in the order.
INFORMATION!
Inspect the packaging carefully for damages or signs of rough handling. Report damage to the
carrier and to the local office of the manufacturer.
INFORMATION!
The remote version will arrive in two cartons. One carton contains the converter and one carton
contains the sensor.
Figure 2-1: Scope of delivery
1 Ordered flowmeter
2 Product documentation
3 Factory calibration report
4 CD-ROM with product documentation in available languages
5 Grounding rings (optional)
6 Signal cable (remote versions only)
INFORMATION!
Assembly materials and tools are not part of the delivery. Use the assembly materials and tools
in compliance with the applicable occupational health and safety directives.

2DEVICE DESCRIPTION
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2.2 Device description
Your measuring device is supplied ready for operation. The factory settings for the operating
data have been made in accordance with your order specifications.
The following versions are available:
áCompact version (the signal converter is mounted directly on the flow sensor)
áRemote version (a measuring sensor with connection box and a separate signal converter)
INFORMATION!
Product specific information and extensive product specification is available using PICK, the
Product Information Center KROHNE web-tool.
PICK can be found via the service menu button on the KROHNE.com website.
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Figure 2-2: Device versions
1 Remote version
2 Compact version with signal converter IFC 300
3 Compact version with signal converter IFC 100 (0°)
4 Compact version with signal converter IFC 100 (45°)
5 Compact version with signal converter IFC 100 (10°) Stainless steel
6 Compact version with signal converter IFC 050 (10°)

DEVICE DESCRIPTION 2
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2.3 Nameplate
INFORMATION!
Check the device nameplate to ensure that the device is delivered according to your order.
Additional information (a.o correct supply voltage), can be found in the documentation of the
signal converter.
1 Name and address of the manufacturer
2 Type designation of the flowmeter and CE sign with number(s) of notified body / bodies
3 Calibration data
4 PED data

3INSTALLATION
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3.1 General notes on installation
3.2 Storage
•Store the device in a dry and dust-free location.
•Avoid lasting direct exposure to the sun.
•Store the device in its original packaging.
•Storage temperature: -50...+70°C / -58...+158°F
3.3 Transport
Signal converter
•No special requirements.
Compact version
•Do not lift the device by the signal converter housing.
•Do not use lifting chains.
•To transport flange devices, use lifting straps. Wrap these around both process connections.
INFORMATION!
Inspect the packaging carefully for damages or signs of rough handling. Report damage to the
carrier and to the local office of the manufacturer.
INFORMATION!
Do a check of the packing list to make sure that you have all the elements given in the order.
INFORMATION!
Look at the device nameplate to ensure that the device is delivered according to your order.
Check for the correct supply voltage printed on the nameplate.
Figure 3-1: Transport

INSTALLATION 3
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3.4 Pre-installation requirements
Make sure that you have all necessary tools available:
•Allen key (4 mm)
•Small screwdriver
•Wrench for cable glands
•Wrench for wall mounting bracket (remote version only)
•Torque wrench for installing flowmeter in pipeline
3.5 General requirements
3.5.1 Vibration
3.5.2 Magnetic field
INFORMATION!
The following precautions must be taken to ensure reliable installation.
• Make sure that there is adequate space to the sides.
• Protect the signal converter from direct sunlight and install a sun shade if necessary.
• Signal converters installed in control cabinets require adequate cooling, e.g. by fan or heat
exchanger.
• Do not expose the signal converter to intense vibration. The flowmeters are tested for a
vibration level in accordance with IEC 68-2-64.
Figure 3-2: Avoid vibrations
Figure 3-3: Avoid magnetic fields

3INSTALLATION
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3.6 Installation conditions
3.6.1 Inlet and outlet
3.6.2 Bends in 2 or 3 dimensions
Figure 3-4: Recommended inlet and outlet
1 Refer to chapter "Bends in 2 or 3 dimensions"
2 t2 DN
INFORMATION!
Sensors of type VN02 up to DN10:
The inlet and outlet sections are enclosed inside the sensor.
Figure 3-5: Inlet when using 2 and/or 3 dimensional bends upstream of the flowmeter
Inlet length: using bends in 2 dimensions: t5 DN; when having bends in 3 dimensions: t10 DN
INFORMATION!
2 Dimensional bends occur in a vertical plane only, while 3 Dimensional bends occur in both
vertical and
andand
and horizontal plane.

INSTALLATION 3
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3.6.3 T-section
3.6.4 Bends
Figure 3-6: Distance behind a T-section
1 t10 DN
Figure 3-7: Installation in bending pipes
Figure 3-8: Installation in bending pipes
CAUTION!
Avoid draining or partial filling of the flow sensor

3INSTALLATION
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3.6.5 Open feed or discharge
3.6.6 Flange deviation
3.6.7 Control valve
Figure 3-9: Installation in front of an open discharge
CAUTION!
Max. permissible deviation of pipe flange faces:
L
max
- L
min
d0.5 mm / 0.02"
Figure 3-10: Flange deviation
1 L
max
2 L
min
Figure 3-11: Installation in front of a control valve

INSTALLATION 3
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3.6.8 Pump
3.6.9 Air venting and vacuum forces
Figure 3-12: Installation behind a pump
Figure 3-13: Air venting
1 t5 m / 17 ft
2 Air ventilation point
Figure 3-14: Vacuum
1 t5 m / 17 ft

3INSTALLATION
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3.6.10 Mounting position
•Install flow sensor in line with the pipe axis.
•Pipe flange faces must be parallel to each other.
Figure 3-15: Mounting position

INSTALLATION 3
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3.7 Mounting
3.7.1 Torques and pressures
Tightening of bolts
• Always tighten the bolts uniformly and in diagonally opposite sequence.
• Do not exceed the maximum torque value.
• Step 1: Apply approx. 50% of max. torque given in table.
• Step 2: Apply approx. 80% of max. torque given in table.
• Step 3: Apply 100% of max. torque given in table.
CAUTION!
Please take care to use the proper gasket to prevent damaging the liner of the flowmeter. In
general, the use of spiral wound gaskets is not advised, as it could severely damage the liner of
the flowmeter.
Figure 3-16: Tightening of bolts
INFORMATION!
Other sizes / pressure ratings on request.

3INSTALLATION
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Nominal
size
DN [mm]
Pressure
rating
Bolts 2Max. torque [Nm] 1
PFA PTFE ETFE PU Hard
rubber
Soft
rubber
2.5 PN 40 4 x M 12 32 32 - - - -
4PN 40 4 x M 12 32 32 - - - -
6PN 40 4 x M 12 32 32 - - - -
10 PN 40 4 x M 12 7.6 7.6 -4.6 - -
15 PN 40 4 x M 12 9.3 9.3 -5.7 - -
20 PN 40 4 x M 12 16 16 -9.6 - -
25 PN 40 4 x M 12 22 22 22 11 - -
32 PN 40 4 x M 16 37 37 37 19 - -
40 PN 40 4 x M 16 43 43 43 25 - -
50 PN 40 4 x M 16 55 55 55 31 -36
65 PN 16 4 x M 16 51 51 51 42 -18
65 PN 40 8 x M 16 38 38 38 21 - -
80 PN 40 8 x M 16 47 47 47 25 -33
100 PN 16 8 x M 16 39 39 39 30 -30
125 PN 16 8 x M 16 53 53 53 40 -43
150 PN 16 8 x M 20 68 68 68 47 -68
200 PN 10 8 x M 20 84 84 84 68 68 50
200 PN 16 12 x M 20 68 68 68 45 45 -
250 PN 10 12 x M 20 78 78 78 65 65 48
250 PN 16 12 x M 24 116 116 116 78 78 -
300 PN 10 12 x M 20 88 88 88 76 76 59
300 PN 16 12 x M 24 144 144 144 105 105 -
350 PN 10 16 x M 20 97 97 97 75 75 67
400 PN 10 16 x M 24 139 139 139 104 104 97
450 PN 10 20 x M 24 - 127 127 93 93 89
500 PN 10 20 x M 24 - 149 149 107 107 103
600 PN 10 20 x M 27 - 205 205 138 138 144
700 PN 10 20 x M 27 - 238 238 163 163 -
800 PN 10 24 x M 30 - 328 328 219 219 -
900 PN 10 28 x M 30 - 308 308 205 205 -
1000 PN 10 28 x M 35 - 392 392 261 261 -
3*
1 The specified torque values are dependent on variables (temperature, bolt material, gasket material,
lubricants, etc.) which are not within the control of the manufacturer. Therefore the values should be re-
garded as indicative only.
2 F= ASTM gr B7 Studbolts - F=0.14 - Carbon steel flanges
3 * Information DN > 1000; please contact the support service department