KROHNE OPTISWITCH 4000 C User manual

OPTISWITCH 4000 C Handbook
Vibrating Level Switch
Transistor (PNP)

2
Contents
OPTISWITCH 4000 C • Transistor (PNP)
42372-EN-191122
Contents
1 About this document ............................................................................................................... 3
1.1 Function ........................................................................................................................... 3
1.2 Target group ..................................................................................................................... 3
1.3 Symbols used................................................................................................................... 3
2 For your safety ......................................................................................................................... 4
2.1 Authorised personnel ....................................................................................................... 4
2.2 Appropriate use................................................................................................................ 4
2.3 Warning about incorrect use............................................................................................. 4
2.4 General safety instructions............................................................................................... 4
2.5 Safety label on the instrument .......................................................................................... 5
2.6 EU conformity................................................................................................................... 5
2.7 Installation and operation in the USA and Canada ........................................................... 5
3 Product description ................................................................................................................. 6
3.1 Conguration.................................................................................................................... 6
3.2 Principle of operation........................................................................................................ 6
3.3 Adjustment ....................................................................................................................... 7
3.4 Supplementary cleaning procedures................................................................................ 7
3.5 Packaging, transport and storage..................................................................................... 8
4 Mounting................................................................................................................................... 9
4.1 General instructions ......................................................................................................... 9
4.2 Mounting instructions ..................................................................................................... 11
5 Connecting to power supply................................................................................................. 13
5.1 Preparing the connection ............................................................................................... 13
5.2 Wiring plan ..................................................................................................................... 14
6 Setup ....................................................................................................................................... 18
6.1 Indication of the switching status.................................................................................... 18
6.2 Simulation ...................................................................................................................... 18
6.3 Function table................................................................................................................. 19
7 Maintenanceandfaultrectication...................................................................................... 20
7.1 Maintenance .................................................................................................................. 20
7.2 Rectify faults................................................................................................................... 20
7.3 How to proceed if a repair is necessary.......................................................................... 21
8 Dismount................................................................................................................................. 22
8.1 Dismounting steps.......................................................................................................... 22
8.2 Disposal ......................................................................................................................... 22
9 Supplement ............................................................................................................................ 23
9.1 Technical data ................................................................................................................ 23
9.2 Dimensions .................................................................................................................... 27
9.3 Trademark ...................................................................................................................... 30
Editing status: 2019-11-21

3
1 About this document
OPTISWITCH 4000 C • Transistor (PNP)
42372-EN-191122
1 About this document
1.1 Function
This instruction provides all the information you need for mounting,
connection and setup as well as important instructions for mainte-
nance,faultrectication,theexchangeofpartsandthesafetyofthe
user. Please read this information before putting the instrument into
operation and keep this manual accessible in the immediate vicinity
of the device.
1.2 Target group
This operating instructions manual is directed to trained personnel.
Thecontentsofthismanualmustbemadeavailabletothequalied
personnel and implemented.
1.3 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 fatal personal injury.
Danger: Non-observance of the information marked with this symbol
results in serious or fatal personal injury.
Ex applications
ThissymbolindicatesspecialinstructionsforExapplications.
• List
The dot set in front indicates a list with no implied sequence.
1 Sequence of actions
Numbers set in front indicate successive steps in a procedure.
Battery disposal
This symbol indicates special information about the disposal of bat-
teries and accumulators.

4
2 For your safety
OPTISWITCH 4000 C • Transistor (PNP)
42372-EN-191122
2 For your safety
2.1 Authorised personnel
All operations described in this documentation must be carried out
onlybytrained,qualiedpersonnelauthorisedbytheplantoperator.
During work on and with the device, the required personal protective
equipment must always be worn.
2.2 Appropriate use
The OPTISWITCH 4000 C is a sensor for point level detection.
Youcannddetailedinformationabouttheareaofapplicationin
chapter "Product description".
Operational reliability is ensured only if the instrument is properly
usedaccordingtothespecicationsintheoperatinginstructions
manual as well as possible supplementary instructions.
For safety and warranty reasons, any invasive work on the device
beyond that described in the operating instructions manual may be
carried out only by personnel authorised by the manufacturer. Arbi-
traryconversionsormodicationsareexplicitlyforbidden.
2.3 Warning about incorrect use
Inappropriate or incorrect use of this product can give rise to applica-
tion-specichazards,e.g.vesseloverll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awlessandreliablecondition.Theoperatorisresponsi-
ble for the trouble-free operation of the instrument. When measuring
aggressive or corrosive media that can cause a dangerous situation
if the instrument malfunctions, the operator has to implement suitable
measures to make sure the instrument is functioning properly.
During the entire duration of use, the user is obliged to determine the
compliance of the necessary occupational safety measures with the
current valid rules and regulations and also take note of new regula-
tions.
The safety instructions in this operating instructions manual, the na-
tional installation standards as well as the valid safety regulations and
accident prevention rules must be observed by the user.
For safety and warranty reasons, any invasive work on the device
beyond that described in the operating instructions manual may be
carried out only by personnel authorised by the manufacturer. Arbi-
traryconversionsormodicationsareexplicitlyforbidden.Forsafety
reasons,onlytheaccessoryspeciedbythemanufacturermustbe
used.

5
2 For your safety
OPTISWITCH 4000 C • Transistor (PNP)
42372-EN-191122
To avoid any danger, the safety approval markings and safety tips on
the device must also be observed and their meaning read in this oper-
ating instructions manual.
2.5 Safety label on the instrument
The safety approval markings and safety tips on the device must be
observed.
2.6 EU conformity
ThedevicefullsthelegalrequirementsoftheapplicableEUdirec-
tives.ByaxingtheCEmarking,weconrmtheconformityofthe
instrument with these directives.
The EU conformity declaration can be found on our homepage.
2.7 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 comply with the relevant requirements of
the Canadian Electrical Code.

6
3 Product description
OPTISWITCH 4000 C • Transistor (PNP)
42372-EN-191122
3 Product description
3.1 Conguration
The scope of delivery encompasses:
• OPTISWITCH 4000 C point level switch
• Test magnet
• Documentation
– This operating instructions manual
– Ifnecessary,certicates
The OPTISWITCH 4000 C consists of the components:
• Housing with electronics
• Processttingwithtuningfork
Fig. 1: OPTISWITCH 4000 C
Thetypelabelcontainsthemostimportantdataforidenticationand
use of the instrument:
• Article number
• Serial number
• Technical data
• Article numbers, documentation
3.2 Principle of operation
OPTISWITCH 4000 C is a point level sensor with tuning fork for point
level detection.
It is designed for industrial use in all areas of process technology and
can be used in liquids.
Typicalapplicationsareoverllanddryrunprotection.Withatuning
fork of only 38 mm length, OPTISWITCH 4000 C can be also mount-
ed e.g. in pipelines from DN 25.The small tuning fork allows use in
vessels, tanks and pipes.Thanks to its simple and robust measuring
system,OPTISWITCH4000Cisvirtuallyunaectedbythechemical
and physical properties of the liquid.
Scope of delivery
Constituent parts
T
ype label
Application area

7
3 Product description
OPTISWITCH 4000 C • Transistor (PNP)
42372-EN-191122
Itfunctionsevenunderdicultconditionssuchasturbulence,airbub-
bles,foamgeneration,buildup,strongexternalvibrationorchanging
products.
Function monitoring
The electronics module of OPTISWITCH 4000 C continuously moni-
tors the following criteria via frequency evaluation:
• Strong corrosion or damage on the tuning fork
• Loss of vibration
• Linebreaktothepiezodrive
If a malfunction is detected or in case of voltage supply, the electron-
icstakesonadenedswitchingstatus,i.e.theoutputisopen(safe
state).
Thetuningforkispiezoelectricallyenergisedandvibratesatitsme-
chanicalresonancefrequencyofapprox.1100Hz.Whenthetuning
fork is submerged in the product, the frequency changes.This change
is detected by the integrated electronics module and converted into a
switching command.
OPTISWITCH 4000 C is a compact instrument, i.e. it can be oper-
ated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 operated directly (e.g. a
warning system, a pump etc.).
Thedataforpowersupplyarespeciedinchapter"Technical data".
3.3 Adjustment
The switching status of OPTISWITCH 4000 C can be checked when
the housing is closed (signal lamp). Products with a density > 0.7 g/
cm³ (0.025 lbs/in³) or ordered optionally with a density > 0.5 g/cm³
(0.018 lbs/in³) can be detected.
3.4 Supplementary cleaning procedures
3.4.1 Oil, grease and silicone-free
The OPTISWITCH 4000 C is also available in the version "Oil, grease
and silicone-free".These instruments have passed through a special
cleaning procedure to remove oil, grease and paint-wetting impair-
ment substances (PWIS).
The cleaning is carried out on all wetted parts as well as on surfaces
accessible from outside.To keep the purity level, the instruments are
immediately packed in plastic foil after the cleaning process.The
purity level remains as long as the instrument is kept in the closed
original packaging.
Caution:
TheOPTISWITCH4000Cinthisversionmustonlybeusedinoxygen
applications.
Functional principle
Voltage supply

8
3 Product description
OPTISWITCH 4000 C • Transistor (PNP)
42372-EN-191122
3.5 Packaging, transport and storage
Your instrument was protected by packaging during transport. Its
capacity to handle normal loads during transport is assured by a test
based on ISO 4180.
The packaging of standard instruments consists of environment-
friendly, recyclable cardboard. For special versions, PE foam or PE
foil is also used. Dispose of the packaging material via specialised
recycling companies.
Transport must be carried out in due consideration of the notes on the
transport packaging. Nonobservance of these instructions can cause
damage to the device.
The delivery must be checked for completeness and possible transit
damage immediately at receipt. Ascertained transit damage or con-
cealed defects must be appropriately dealt with.
Up to the time of installation, the packages must be left closed and
stored according to the 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 %
Packaging
Transport
Transport inspection
Storage
Storage and transport
temperature

9
4 Mounting
OPTISWITCH 4000 C • Transistor (PNP)
42372-EN-191122
4 Mounting
4.1 General instructions
Make sure that all parts of the instrument coming in direct contact
with the process, especially the sensor element, process seal and
processtting,aresuitablefortheexistingprocessconditions,such
as process pressure, process temperature as well as the chemical
properties of the medium.
Youcanndthespecicationsinchapter"Technical data" and on the
nameplate.
Theinstrumentissuitableforstandardandextendedambientcondi-
tions acc. to DIN/EN/IEC/ANSI/ISA/UL/CSA 61010-1.
In general, OPTISWITCH 4000 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.
Keep in mind that the swichting point can vary dependent on the
installation position.
The switching point refers to the medium water (1 g/cm³/0.036 lbs/
in³). Please keep in mind that the switching point of the instrument
shiftswhenthemediumhasadensitydieringfromwater.
2
3
1
11 mm
(0.43")
34 mm
(1.34")
Fig. 2: Vertical mounting
1 Switching point in water
2 Switching point with lower density
3 Switching point with higher density
Suitability for the process
conditions
Suitability for the ambient
conditions
Switching point

10
4 Mounting
OPTISWITCH 4000 C • Transistor (PNP)
42372-EN-191122
2
1
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 gland. Rain and condensation water can thus drain
o.Thisappliesmainlytooutdoormountingaswellasinstallationin
areaswherehighhumidityisexpected(e.g.throughcleaningpro-
cesses) or on cooled or heated vessels.
Fig. 4: Measures against moisture ingress
Do not hold OPTISWITCH 4000 C on the tuning fork.
Theprocesstting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speciedinchapter"Technical
data" or on the type label of the sensor.
Moisture
Transport
Pressure/Vacuum

11
4 Mounting
OPTISWITCH 4000 C • Transistor (PNP)
42372-EN-191122
The vibrating level switch is a measuring instrument and must be
treated accordingly. Bending the vibrating element will destroy the
instrument.
Warning:
The housing must not be used to screw the instrument in! Applying
tightening force can damage internal parts of the housing.
Usethehexagonabovethethreadforscrewingin.
4.2 Mounting instructions
For threaded versions of OPTISWITCH 4000 C in combination with a
mounting boss with O-ring in front and welding marking.
OPTISWITCH4000Cwiththreadsizes¾"and1"haveadened
thread.This means that every OPTISWITCH 4000 C is in the same
positionafterbeingscrewedin.Removethereforethesuppliedat
sealfromthethreadofOPTISWITCH4000C.Thisatsealisnot
requiredwhenusingaweldedsocketwithfront-ushseal.
Before welding, unscrew OPTISWITCH 4000 C and remove the rub-
ber ring from the welded socket.
Theweldedsocketisprovidedwithamarking(notch).Forhorizontal
mounting, weld the socket with the notch facing upward or downward;
inpipelines(DN25toDN50)alignedwiththedirectionofow.
1
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 indicated
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sucienttoreachtherecommendedinstal-
lation position.
In adhesive and viscous products, the surfaces of the tuning fork
should protrude into the vessel to avoid buildup.Therefore sockets for
angesandmountingsbossesshouldnotexceedacertainlength.
Handling
Welded socket
Adhesive products

12
4 Mounting
OPTISWITCH 4000 C • Transistor (PNP)
42372-EN-191122
30 mm
(1.18")
Fig. 6: Adhesive products
IfOPTISWITCH4000Cismountedinthellingstream,unwanted
false measurement signals can be generated. For this reason, mount
OPTISWITCH 4000 C at a position in the vessel where no disturbanc-
es,e.g.fromllingopenings,agitators,etc.,canoccur.
To make sure the tuning fork of OPTISWITCH 4000 C generates as
littleresistanceaspossibletoproductow,mountthesensorsothat
the surfaces are parallel to the product movement.
Inowingmedium
Productow

13
5 Connecting to power supply
OPTISWITCH 4000 C • Transistor (PNP)
42372-EN-191122
5 Connecting to power supply
5.1 Preparing the connection
Always keep in mind the following safety instructions:
Warning:
Connect only in the complete absence of line voltage.
• The electrical connection must only be carried out by trained,
qualiedpersonnelauthorisedbytheplantoperator.
• Alwaysswitchopowersupply,beforeconnectingordisconnect-
ing the instrument.
The instrument is connected with standard three-wire cable without
screen.Ifelectromagneticinterferenceisexpectedwhichisabovethe
test values of EN 61326 for industrial areas, screened cable should
be used.
Use cable with round cross section. Depending on the plug connec-
tion, you have to select the outer diameter of the cable respectively so
thatthesealeectofthecableglandisensured.
• Valve plug ISO 4400, ø 4.5 … 7 mm
• Valve plug ISO 4400 with IDC crimping technology, ø 5.5 … 8 mm
Use cable with a round wire cross section and tighten the cable gland.
Make sure that the cable used has the required temperature resist-
anceandresafetyformax.occurringambienttemperature
When mounting outdoors, on cooled vessels or in moist areas in
which cleaning is made with steam or high pressure, the sealing of
the cable gland is very important.
Note safety instructions
Connection cable
Cable glands

14
5 Connecting to power supply
OPTISWITCH 4000 C • Transistor (PNP)
42372-EN-191122
5.2 Wiring plan
1 2 3
Fig. 7: Overview of the connection versions
1 M12 x 1 plug connection
2 Valve plug ISO 4400
3 Valve plug ISO 4400 with IDC method of termination
M12 x 1 plug connection
This plug connection requires a prefabricated cable with plug. De-
pending on the version, protection IP66/IP67 or IP68 (0.2 bar).
Valve plug ISO 4400
For this plug version, standard cable with round wire cross-section
can be used. Cable diameter 4.5 … 7 mm, protection IP65.
Housing overview
Plug versions

15
5 Connecting to power supply
OPTISWITCH 4000 C • Transistor (PNP)
42372-EN-191122
1
4
5
6
7
8
9
10
2 3
Fig. 8: Connection, valve plug ISO 4400
1 Pressure screw
2 Pressure disc
3 Seal ring
4 Fixing screw
5 Seal washer
6 Plug housing
7 Plug insert
8 Proleseal
9 Control lamp
10 OPTISWITCH 4000 C
Valve plug ISO 4400 with IDC method of termination
For this plug version you can use standard cable with round wire
cross-section.The inner conductors do not have to be stripped.The
plug connects the conductors automatically when screwing in. Cable
diameter 5.5 … 8 mm, protection IP67.
1 2 3 4
5
Fig. 9: Connection, valve plug ISO 4400 with IDC crimping technology
1 Compression nut
2 Cable
3 Seal ring
4 Terminal insert
5 Plug housing

16
5 Connecting to power supply
OPTISWITCH 4000 C • Transistor (PNP)
42372-EN-191122
For connection to binary inputs of a PLC.
Max. Min.
3
21
3
21
-+
R
L
R
L
-+
PA PA
Fig. 10: Wiring plan, Transistor output with valve plug ISO 4400
PA Potential equalisation
RLLoad resistance (contactor, relay, etc.)
Transistor output

17
5 Connecting to power supply
OPTISWITCH 4000 C • Transistor (PNP)
42372-EN-191122
R
L
R
L
1
4
2
3
1
4
2
3
-
Max. Min.
-
++
Fig. 11: Wiring plan (housing), transistor output with M12 x 1 plug connection
1 Brown
2 White
3 Blue
4 Black
RLLoad resistance (contactor, relay, etc.)

18
6 Setup
OPTISWITCH 4000 C • Transistor (PNP)
42372-EN-191122
6 Setup
6.1 Indication of the switching status
The switching status of the electronics can be checked via the signal
lamps (LEDs) integrated in the upper part of the housing.
The signal lamps have the following meaning:
• Green lights - voltage supply connected
• Yellow lights - vibrating element covered
• Redlightsbriey-functiontestduringinstrumentstart(for0.5s)
• Red lights - shortcircuit or overload in the load circuit (sensor
output high-impedance)
• Redashes-Erroronthevibratingelementortheelectronics
(sensor output high impedance)
6.2 Simulation
The OPTISWITCH 4000 C has an integrated function for simulation
of the output signal which can be activated magnetically. Please
proceed as follows:
→ Hold the test magnet (accessory) against the circle symbol with
the label "TEST" on the instrument housing
Fig. 12: Simulation of the output signal
The test magnet changes the current switching condition of the instru-
ment.You can check the change on the signal lamp. Please note that
all connected device are activated during the simulation.
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 try it 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:
It is absolutely necessary that you remove the test magnet from the
instrument housing after the simulation.

19
6 Setup
OPTISWITCH 4000 C • Transistor (PNP)
42372-EN-191122
6.3 Function table
The following table provides an overview of the switching conditions
depending on the set mode and the level.
Level Switching sta-
tus
Control lamp
Yellow - cov-
erage
Control lamp
Green - voltage
indication
Control lamp
Red - fault sig-
nal
Max.modeofop-
eration
closed
Max.modeofop-
eration
open
Min. mode of op-
eration
closed
Min. mode of op-
eration
open
Fault any open any

20
7Maintenanceandfaultrectication
OPTISWITCH 4000 C • Transistor (PNP)
42372-EN-191122
7 Maintenanceandfaultrectication
7.1 Maintenance
If the device is used properly, no special maintenance is required in
normal operation.
The cleaning helps that the type label and markings on the instrument
are visible.
Take note of the following:
• Use only cleaning agents which do not corrode the housings, 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oersmaximumreliability.Nevertheless,faultscanoccur
during operation.These may be caused by the following, e.g.:
• Sensor
• Process
• Voltage supply
• Signal processing
Therstmeasuretotakeistochecktheoutputsignal.Inmanycases,
thecausescanbedeterminedthiswayandthefaultsquicklyrectied.
Error Cause Rectication
Green signal
lampo
Voltage supply in-
terrupted.
Check the voltage supply and the ca-
ble connection
Electronics de-
fective
Exchangetheinstrumentorsenditin
for repair
Red signal lamp
lights (switching
output high-im-
pedance)
Error with the
electrical con-
nection
Connect the instrument according to
the wiring plan
Shortcircuit or
overload
Check the electrical connection
Red signal lamp
ashes(switching
output high-im-
pedance)
Vibrating fre-
quency out of
specication
Check the vibrating element on build-
up and remove it
Buildup on the vi-
brating element
Check the vibrating element and
the sensor if there is buildup and re-
move it
Vibrating element
damaged
Check if the vibrating element is dam-
ageorextremelycorroded
Maintenance
Cleaning
Reaction when malfunc-
tion occurs
Causes of malfunction
Faultrectication
Checking the switching
signal