KROHNE OPTIFLUX 4000 User manual

Electromagnetic flow sensor
OPTIFLUX 4000
OPTIFLUX 4000OPTIFLUX 4000
OPTIFLUX 4000 Quick Start
Quick StartQuick Start
Quick Start
© KROHNE 10/2021 - 4003872405 - QS OPTIFLUX 4000 R08 en
The documentation is only complete when used in combination with the relevant
documentation for the signal converter.

CONTENTS
2
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OPTIFLUX 4000
1 Safety instructions 3
2 Installation 4
2.1 Scope of delivery............................................................................................................... 4
2.2 Device description ............................................................................................................ 5
2.3 Nameplate ........................................................................................................................ 6
2.4 Storage ............................................................................................................................. 7
2.5 Transport .......................................................................................................................... 7
2.6 Pre-installation requirements ......................................................................................... 7
2.7 General requirements ...................................................................................................... 8
2.7.1 Vibrations ................................................................................................................................ 8
2.7.2 Magnetic field.......................................................................................................................... 8
2.8 Installation conditions ...................................................................................................... 9
2.8.1 Inlet and outlet ........................................................................................................................ 9
2.8.2 Bends in 2 or 3 dimensions..................................................................................................... 9
2.8.3 Bends .................................................................................................................................... 10
2.8.4 T-section ............................................................................................................................... 11
2.8.5 Open discharge ..................................................................................................................... 11
2.8.6 Pump ..................................................................................................................................... 11
2.8.7 Control valve ......................................................................................................................... 12
2.8.8 Air venting and vacuum forces ............................................................................................. 12
2.8.9 Flange deviation.................................................................................................................... 13
2.8.10 Mounting position................................................................................................................ 13
2.9 Mounting ......................................................................................................................... 14
2.9.1 Torques and pressures......................................................................................................... 14
2.9.2 Temperatures ....................................................................................................................... 17
3 Electrical connections 18
3.1 Safety instructions.......................................................................................................... 18
3.2 Grounding ....................................................................................................................... 18
3.3 Virtual reference option ................................................................................................. 20
3.4 Connection diagrams ..................................................................................................... 20
4 Technical data 21
4.1 Dimensions and weights ................................................................................................ 21
4.2 Vacuum load ................................................................................................................... 26
5 Notes 27

SAFETY INSTRUCTIONS 1
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Warnings and symbols used
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.
Safety instructions for the operator
DANGER!
This information refers to the immediate danger when working with electricity.
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.
CAUTION!
Installation, assembly, start-up and maintenance may only be performed by appropriately
trained personnel. The regional occupational health and safety directives must always be
observed.
LEGAL NOTICE!
The responsibility as to the suitability and intended use of this device rests solely with the user.
The supplier assumes no responsibility in the event of improper use by the customer. Improper
installation and operation may lead to loss of warranty. In addition, the "Terms and Conditions of
Sale" apply which form the basis of the purchase contract.
INFORMATION!
• Further information can be found in the manual, on the data sheet, in special manuals,
certificates and on the manufacturer's website.
• If you need to return the device to the manufacturer or supplier, please fill out the form
contained in the manual and send it with the device. Unfortunately, the manufacturer cannot
repair or inspect the device without the completed form.

2INSTALLATION
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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 signal converter and one
carton contains the flow sensor.
Figure 2-1: Scope of delivery
1 Ordered flowmeter
2 Product documentation
3 Factory calibration report
4 Grounding rings (optional)
5 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.

INSTALLATION 2
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2.2 Device description
Electromagnetic flowmeters are designed exclusively to measure the flow and conductivity of
electrically conductive, liquid media.
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:
•Compact version (the signal converter is mounted directly on the flow sensor)
•Remote version (electrical connection to the flow sensor via field current and signal cable)
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.
Figure 2-2: Device versions
1 Remote version (example with IFC 300 F / IFC 400 F remote converter)
2 Compact version with signal converter IFC 300/ IFC 400
3 Compact version with signal converter IFC 100 (0°)
4 Compact version with signal converter IFC 100 (45°)
5 Compact version with stainless steel signal converter IFC 100 (10°)
6 Compact version with signal converter IFC 050 (10°)

2INSTALLATION
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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 (e.g. 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, serial number, manufacturing date and country of origin
3 Calibration data, size and protection category
4 PED data conform applicable standard
5 Data matrix
6 Additional info and/or approvals related information
7 Product certification and/or other marking
8 Conformity mark (e.g. CE/UKCA) with number(s) of notified body/bodies and disposal logo

INSTALLATION 2
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2.4 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: -40...+70°C / -40...+158°F
2.5 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.
2.6 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
Figure 2-3: Transport

2INSTALLATION
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2.7 General requirements
2.7.1 Vibrations
2.7.2 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 vibrations and mechanical shocks. The
measuring devices are tested for a vibration/shock level as described in the chapter
"Technical data" in the manual and the technical documentation.
• Avoid magnetic field! Keep at least 5 DN distance between electromagnetic flow sensors.
Figure 2-4: Avoid vibrations
Figure 2-5: Avoid magnetic field

INSTALLATION 2
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2.8 Installation conditions
2.8.1 Inlet and outlet
2.8.2 Bends in 2 or 3 dimensions
Figure 2-6: 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 2-7: 2 and/or 3 dimensional bends upstream of the flowmeter
1 2 dimensions = X/Y
2 3 dimensions = X/Y/Z
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 or
oror
or horizontal plane (X/Y) only, while 3 dimensional bends
occur in both vertical and
andand
and horizontal plane (X/Y/Z).

2INSTALLATION
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2.8.3 Bends
Figure 2-8: Installation in bending pipes (90°)
INFORMATION!
Recommended installation positions are at a lowered or ascending section of the pipeline
installation. Installation at the highest point will enlarge the risk of flowmeter malfunction,
because of air/gas bubbles.
Vertical installation in combination with an open surcharge has to be avoided.
Vertical installation with a controlled back-pressure is possible.
Figure 2-9: Installation in bending pipes (45°)
INFORMATION!
Vertical installation on a descending slope in the pipeline is only recommended when the back-
pressure is controlled.
CAUTION!
Avoid draining or partial filling of the flow sensor

INSTALLATION 2
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2.8.4 T-section
2.8.5 Open discharge
2.8.6 Pump
Figure 2-10: Distance behind a T-section
1 t10 DN
Figure 2-11: Installation in front of an open discharge
Figure 2-12: Installation behind a pump
INFORMATION!
Recommended position to install a flowmeter is downstream a pump (on a position where the
flow disturbances of the pump are resolved).
An electromagnetic flowmeter can be installed in the suction line of a pump if there is no
cavitation in the pipeline system.

2INSTALLATION
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2.8.7 Control valve
2.8.8 Air venting and vacuum forces
Figure 2-13: Installation in front of a control valve
INFORMATION!
Recommended position to install a flowmeter is upstream a control valve.
An electromagnetic flowmeter can be installed downstream of the control valve if there is no
cavitation in the pipeline system (e.g. flow profile disturbances are resolved).
Figure 2-14: Air venting
1 t5 m / 17 ft
2 Air ventilation point
Figure 2-15: Vacuum
1 t5 m / 17 ft

INSTALLATION 2
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2.8.9 Flange deviation
2.8.10 Mounting position
•Install the flow sensor with the signal converter aligned upwards or downwards.
•Install the flow sensor in line with the pipe axis.
•Pipe flange faces must be parallel to each other.
CAUTION!
Max. permissible deviation of pipe flange faces:
L
max
- L
min
d0.5 mm / 0.02"
Figure 2-16: Flange deviation
1 L
max
2 L
min
Figure 2-17: Mounting position

2INSTALLATION
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2.9 Mounting
2.9.1 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 2-18: Tightening of bolts

INSTALLATION 2
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INFORMATION!
Other sizes / pressure ratings on request.
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 -----
4PN 40 4 x M 12 32 -----
6PN 40 4 x M 12 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 -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 68 68 50
200 PN 16 12 x M 20 -68 68 45 45 -
250 PN 10 12 x M 20 -78 78 65 65 48
250 PN 16 12 x M 24 -116 116 78 78 -
300 PN 10 12 x M 20 -88 88 76 76 59
300 PN 16 12 x M 24 -144 144 105 105 -
350 PN 10 16 x M 20 -97 97 75 75 67
400 PN 10 16 x M 24 -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

2INSTALLATION
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Nominal
size
[inch]
Flange
class
[lb]
Bolts 2Max. torque [in-lb] 1
PFA PTFE ETFE PU Hard
rubber
Soft
rubber
1/10 150 4 x 1/2" 39 - - - - -
1/6 150 4 x 1/2" 39 - - - - -
1/4 150 4 x 1/2" 39 - - - - -
3/8 150 4 x 1/2" 39 39 - - - -
1/2 150 4 x 1/2" 34 34 - - - -
3/4 150 4 x 1/2" -50 - - - -
1150 4 x 1/2" 67 67 67 - - -
1 1/4 150 4 x 1/2" 97 97 97 - - -
1 1/2 150 4 x 1/2" 138 138 138 - - -
2150 4 x 5/8" 225 225 225 - - 158
3150 4 x 5/8" 380 380 380 - - 283
4150 8 x 5/8" 300 300 300 - - 207
6150 8 x 3/4" 540 540 540 - - 328
8150 8 x 3/4" -979 979 818 818 418
10 150 12 x 7/8" -1104 1104 923 923 601
12 150 12 x 7/8" -1478 1478 1237 1237 676
14 150 12 x 1" -1835 1835 1538 1538 909
16 150 16 x 1" -1767 1767 1481 1481 1141
18 150 16 x 1 1/8" -2605 2605 2183 2183 1100
20 150 20 x 1 1/8" -2365 2365 1984 1984 1618
24 150 20 x 1 1/4" -3419 3419 2873 2873 1479
28 150 28 x 1 1/4" -2904 2904 -3* 2155
32 150 28 x 1 1/2" -4560 4560 - * -
36 150 32 x 1 1/2" - -3* - * -
40 150 36 x 1 1/2" - - * - * -
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 * ; please contact the support service department
INFORMATION!
Other sizes / pressure ratings on request.
CAUTION!
• Pressures are applicable at 20 ° C / 68 ° F.
• For higher temperatures, the pressure ratings are as per ASME B16.5.

INSTALLATION 2
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2.9.2 Temperatures
CAUTION!
Protect the device from direct sunlight.
Temperature range Process [°C] Ambient [°C] Process [°F] Ambient [°F]
min. max. min. max. min. max. min. max.
PTFE & PFA
Remote flow sensor -40 180 -40 65 -40 356 -40 149
Compact with IFC 300 / IFC 400 1 -40 140 -40 65 -40 284 -40 149
Compact with IFC 100 / IFC 050 2 -40 120 -40 65 -40 248 -40 149
ETFE
Remote flow sensor -40 120 -40 65 -40 248 -40 149
Compact with IFC 300 / IFC 400 1
Compact with IFC 100 / IFC 050
Hard rubber
Remote flow sensor -5 80 -40 65 23 176 -40 149
Compact with IFC 300 / IFC 400 1
Compact with IFC 100 / IFC 050
PU
Remote flow sensor -5 65 -40 65 23 149 -40 149
Compact with IFC 300 / IFC 400 1
Compact with IFC 100 / IFC 050
1Maximum ambient temperature for IFC 400 in combination with fan only. For specific conditions of the ambient tem-
perature, please refer to the documentation of the IFC 400 converter.
2Max. ambient temperature is 60°C / 140°F, but process temperature is then limited to 60°C / 140°F.
INFORMATION!
Ambient temperatures below -25
° C / -13 ° F may affect the readability of the display
INFORMATION!
The maximum ambient temperature for the IFC 100 stainless steel compact version is 5
° C / 9 ° F
lower than the standard compact versions.

3ELECTRICAL CONNECTIONS
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3.1 Safety instructions
3.2 Grounding
DANGER!
All work on the electrical connections may only be carried out with the power disconnected.
Take note of the voltage data on the nameplate!
DANGER!
Observe the national regulations for electrical installations!
DANGER!
For devices used in hazardous areas, additional safety notes apply; please refer to the Ex
documentation.
WARNING!
Observe without fail the local occupational health and safety regulations.
Any work done on the electrical components of the measuring device may only be carried out by
properly trained specialists.
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.
DANGER!
The device must be grounded in accordance with regulations in order to protect personnel
against electric shocks.
Figure 3-1: Grounding
Metal pipelines, not internally coated. Grounding without grounding rings.

ELECTRICAL CONNECTIONS 3
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Grounding ring number 1:
•dDN300 / 12": 3 mm / 0.12"
•tDN350 / 14": 4 mm / 0.16"
(tantalum: 0.5 mm / 0.02")
Grounding ring number 2:
•dDN300 / 12": 3 mm / 0.12"
•tDN350 / 14": 4 mm / 0.16"
•Prevents damage to the flanges during transport and installation
•Especially for flow sensors with PTFE liner
Grounding ring number 3:
•dDN300 / 12": 3 mm / 0.12"
•tDN350 / 14": 4 mm / 0.16"
•With cylindrical neck (length 30 mm / 1.25" for DN10...150 / 3/8...6")
•Offers liner protection against abrasive fluids
Figure 3-2: Different types of grounding rings
1 Grounding ring number 1
2 Grounding ring number 2
3 Grounding ring number 3

3ELECTRICAL CONNECTIONS
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3.3 Virtual reference option
for:
- IFC 300 (C, W and F version)
- IFC 400 (C and F version)
Benefits of virtual reference:
•Grounding rings or grounding electrodes can be omitted.
•Safety increases by reducing the number of potential leakage points.
•The installation of the flowmeters is much easier.
Minimum requirements:
•Size: tDN10 / 3/8"
•Electrical conductivity: t200 μS/cm
•Signal cable: max. 50 m / 164 ft, type DS
3.4 Connection diagrams
Figure 3-3: Virtual reference
INFORMATION!
For the connection diagrams refer to the documentation of the applicable signal converter.
INFORMATION!
Virtual reference cannot be activated when the IFC 400 is in the SIL mode.