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.
lList
The dot set in front indicates a list with no implied sequence.
àAction
This arrow indicates a single action.
1Sequence
Numbers set in front indicate successive steps in a procedure.
31763-EN-060830
OPTISWITCH 4000 C - with transistor output3
Page 4
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 isin CE conformity with NSR (73/23/EWG).
Conformity has been judged according to the following
standards:
l EMC:
- Emission EN 61326: 1997 (class B)
- Susceptibility EN 61326: 1997/A1:1998
l LVD: EN 61010-1: 2001
4OPTISWITCH 4000 C - with transistor output
31763-EN-060830
Page 5
3 Product description
3.1 Configuration
Product description
Scope of delivery
Components
The scope of delivery encompasses:
l OPTISWITCH 4000 C level sensor
l Test magnet
l Documentation
- this operating instructions manual
- if necessary, certificates
OPTISWITCH 4000 C consists of the following components:
l Housing with electronics
l process fitting with tuning fork
Fig. 1: OPTISWITCH 4000 C
3.2 Principle of operation
Area of application
31763-EN-060830
OPTISWITCH 4000 C - with transistor output5
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
Page 6
Product description
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 such 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:
l Strong corrosion or damage on the tuning fork
l loss of vibration
l 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).
Physical principle
Power supply
Packaging
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
>0.7 g/cm³ (>0.025 lbs/in³) can be detected.
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.
31763-EN-060830
6OPTISWITCH 4000 C - with transistor output
Page 7
Product description
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 temperature
l Storage and transport temperature see "Supplement -
Technical data - Ambient conditions"
l Relative humidity 20 … 85 %
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OPTISWITCH 4000 C - with transistor output7
Page 8
Mounting
4 Mounting
4.1 General instructions
Switching point
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/cm³ or 0.036 lbs/in³). When mountingOPTISWITCH 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.
2
")
")
64
/
33
13mm
(
64
/
33
13mm
(
1
3
Fig. 2: Vertical mounting
1Switching point approx. 13 mm (0.51 in)
2Switching point with lower density
3Switching point with higher density
8OPTISWITCH 4000 C - with transistor output
31763-EN-060830
Page 9
Mounting
1
2
Fig. 3: Horizontal mounting
1Switching point
2Switching point (recommended mounting position - particularly for adhesive
products)
Moisture
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
Transport
31763-EN-060830
OPTISWITCH 4000 C - with transistor output9
Do not hold OPTISWITCH 4000 C on the tuning fork.
Page 10
Mounting
Pressure/Vacuum
Handling
Welded socket
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:
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.
10OPTISWITCH 4000 C - with transistor output
31763-EN-060830
Page 11
Fig. 5: Marking on the welded socket
1Marking
Mounting
1
Adhesive products
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 sufficient 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.
30mm
3
/16")
(1
Fig. 6: Adhesive products
31763-EN-060830
OPTISWITCH 4000 C - with transistor output11
Page 12
Mounting
Inflowing medium
Flows
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.
12OPTISWITCH 4000 C - with transistor output
31763-EN-060830
Page 13
Connecting to voltage supply
5 Connecting to voltage supply
5.1 Preparing the connection
Note safety instructions
Selecting the connection ca-
ble
Cable glands
Generally not the following safety instructions:
l 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.
l Valve plug DIN 43650, ø 4.5 … 7 mm
l Valve plug IDC method of termination DIN 43650,
ø 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.
31763-EN-060830
OPTISWITCH 4000 C - with transistor output13
Page 14
Connecting to voltage supply
Housing overview
5.2 Wiring plan
123
Fig. 7: Overview of the connection versions
1M12x1 plug connection
2Valve plug DIN 43650
3Valve plug DIN 43650 with IDC method of termination
Plug versions
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 crosssection can be used. Cable diameter 4.5 … 7 mm, protection
IP 65.
14OPTISWITCH 4000 C - with transistor output
31763-EN-060830
Page 15
Connecting to voltage supply
4
5
1
23
6
7
8
10
Fig. 8: Connection, valve plug DIN 43650
1Pressure screw
2Pressure disk
3Seal ring
4Fixing screw
5Seal washer
6Plug housing
7Plug insert
8Profile seal
9Control lamp
10 OPTISWITCH 4000 C
9
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 … 8.0 mm, protection IP 67.
For connection to binary inputs of a PLC with an input
resistance <100 kOhm.
Max.Min.
2323
21
3
R
L
-+
10... 55V DC10... 55V DC
PA
Fig. 10: Wiring plan - Transistor output with valve plug DIN 43650
PA Potential equalisation
RL Load resistor (contactor, relay etc.)
-+
PA
21
3
R
L
16OPTISWITCH 4000 C - with transistor output
31763-EN-060830
Page 17
Connecting to voltage supply
Max.
Min.
1214
2
2
1
3
4
R
L
-
+
10... 55V DC10... 55V DC
Fig. 11: Wiring plan (housing)-Transistor output with M12x1 plug connection
1Brown
2White
3Blue
4Black
RL Load resistor (contactor, relay etc.)
1
3
4
R
L
-
+
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OPTISWITCH 4000 C - with transistor output17
Page 18
Set up
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:
à Hold the test magnet (accessory) to the magnet symbol on
the instrument housing
Fig. 12: Function test
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:
18OPTISWITCH 4000 C - with transistor output
31763-EN-060830
Page 19
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.
LevelSwitching statusControl lamp
Mode max.
transistor conductsGreen
Mode max.
Mode min.
Mode min.
Failureanytransistor blocksflashes red
transistor blocksred
transistor conductsGreen
transistor blocksred
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OPTISWITCH 4000 C - with transistor output19
Page 20
Maintenance and fault rectification
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
Causes of malfunction
Fault rectification
Checking the switching signal
OPTISWITCH 4000 C offers maximum reliability. Nevertheless
faults can occur during operation. These may be caused by the
following, e.g.:
l Sensor
l Process
l Power supply
l 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
l Voltage supply interrupted.
à Check the voltage supply and the cable connection
à Exchange the electronics module
? Signal lamp flashes red
l There was no load connected when connecting to
power supply
à Connect the instrument correctly
à Check if the tuning fork is damage or extremely
corroded
l Frequency error
à Adjust the instrument correctly
? The signal lamp flashes alternately red and green
l Shortcircuit or overload
à Check the electrical connection
20OPTISWITCH 4000 C - with transistor output
31763-EN-060830
Page 21
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 insert a
new electronics module. T he housing seal is supplied with the
electronics module.
You require an electronics module type SWE50T or SWE50C.
If you want to use an electronics module with another signal
output (e.g. contactless electronic switch SWE50C), you can
download the suitable operating instructions 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:
1 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)
3 Remove valve plug (2) or M12x1 acc. to drawing
4 R
emove lateral fixing screw (7) with a crosstip screwdriver
5 Pull electronics module (4) carefully out of the housing (8)
6 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,
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.
make sure that
31763-EN-060830
OPTISWITCH 4000 C - with transistor output21
Page 22
Maintenance and fault rectification
1
2
3
4
5
6
7
8
Fig. 13: Exchange the electronics
1Fixing screw
2Valve plug DIN 43650
3Profile seal
4Electronics module
5Rotary switch (16-steps)
6Plug connector
7Fixing screw
8Housing
7.4 Instrument repair
If a repair is necessary, please proceed as follows:
You can download a return form from our websitekrohne-mar.com/fileadmin/media-lounge/PDF-Download/
22OPTISWITCH 4000 C - with transistor output
http://www.
31763-EN-060830
Page 23
Maintenance and fault rectification
Specimen_e.pdf.
By doing this you help us carry out the repair quickly and
without having to call back for needed information.
l Print and fill out one form per instrument
l Clean the instrument and pack it damage-proof
l Attach the completed form and possibly also a safety data
sheet to the instrument
31763-EN-060830
OPTISWITCH 4000 C - with transistor output23
Page 24
Dismounting
8 Dismounting
8.1 Dismounting procedure
Warning:
Before dismounting, be aware of dangerous process conditions 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 directive 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.
24OPTISWITCH 4000 C - with transistor output
31763-EN-060830
Page 25
9 Supplement
9.1 Technical data
General data
Material 316L corresponds to 1.4404 or 1.4435
Materials, wetted parts
- Tuning fork316L
- Process sealKlingersil C-4400
- Process fittings316L
Materials, non-wetted parts
- Housing316L and plastic PEI
Weightapprox. 250 g (ca. 9 oz)
Process fittings
- ThreadG¾ A, G1 A, ¾ NPT or 1 NPT
- hygienic fittingsTri-Clamp 1", Tri-Clamp 1½"
PN 40, bolting DN 40 PN 40, SMS
Surface quality
- StandardR
- hygienic versionR
<3.2 µm (1.26-4in)
a
<0.8 µm (3.15-5in)
a
, bolting DN 25
Supplement
Measuring accuracy
Hysteresisapprox. 2 mm (0.08 in) with vertical installation
Integration timeapprox. 500 ms
Frequencyapprox. 1200 Hz
Ambient conditions
Ambient temperature on the housing-40 … +70 °C (-40 … +158 °F)
Storage and transport temperature-40 … +80 °C (-40 … +176 °F)
Process conditions
Process pressure-1 … 64 bar (-14.5 … 938 psi)
Process temperature - Standard-40 … +100 °C (-40 … +212 °F)
- Connection frequency10 x (to the same cross-section)
26OPTISWITCH 4000 C - with transistor output
31763-EN-060830
Page 27
Electrical protective measures
Protection
- Valve plug (DIN 43650)IP 65
- Valve plug IDC method of termina-
IP 67
tion (DIN 43650)
- M12x1 plug connectionIP 66/IP 67
Overvoltage categoryIII
Protection classII
Approvals
Overfill protection acc. to WHG
Supplement
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OPTISWITCH 4000 C - with transistor output27
Page 28
Supplement
9.2 Dimensions
OPTISWITCH 4000 C, standard version
23
36mm
(1 27/64")
27mm
1
/16")
(1
")
8
1
M12x1
")
64
/
25
10mm
(
ø31,7mm
1
/4")
")
64
/
37
40mm
(1
")
64
/
33
13mm
(
(1
32
3
/4A, 3/4"NPT
G
G1A, 1"NPT
ø21,3mm
27
/32")
(
")
32
/
7
132,5mm (5
L
Fig. 14: OPTISWITCH 4000 C, standard version
1Thread G¾ A, G1 A, ¾ NPT or 1 NPT (M12x1)
3
35mm
")
32
/
7
158mm (6
1)
/
(1
")
2
/
1
165mm (6
2Thread G¾ A, G1 A, ¾ NPT or 1 NPT (valve plug DIN 43650)
3Thread G¾ A, G1 A, ¾ NPT or 1 NPT (valve plug DIN 43650 with IDC method of termination)
4Switching point
LLength with G¾ A, ¾ NPT: 66 mm (2.6 in)
LLength with G1 A, 1 NPT: 69 mm (2.7 in)
LLength with switching point = L + 48 mm (1.9 in)
")
32
/
21
42mm
(1
28mm
(1
7
/64")
42mm
(1
21
/32")
4
1)
Keep in mind that the total length is extended by the plug connection.
28OPTISWITCH 4000 C - with transistor output
31763-EN-060830
Page 29
OPTISWITCH 4000 C, high temperature version
Supplement
23
36mm
27
/64")
(1
27mm
1
/16")
(1
21
42mm
")
64
/
11
182mm (7
")
32
/
(1
1
M12x1
")
64
/
25
10mm
(
ø31,7mm
1
(1
")
64
/
37
(1
13mm
/4")
32
G3/4A, 3/4"NPT
G1A, 1"NPT
ø21,3mm
27
/32")
(
")
64
/
33
(
")
64
/
25
162,5mm (6
L
40mm
Fig. 15: OPTISWITCH 4000 C, high temperature version
1Thread G¾ A, G1 A, ¾ NPT or 1 NPT (M12x1)
35mm
")
32
/
13
188mm (7
2)
")
8
/
3
(1
2Thread G¾ A, G1 A, ¾ NPT or 1 NPT (valve plug DIN 43650)
3Thread G¾ A, NPT or 1 NPT (valve plug DIN 43650 with with IDC method of termination)
4Switching point
LLength with G¾ A, ¾ NPT: 66 mm (2.6 in)
LLength with G1 A, 1 NPT: 69 mm (2.7 in)
LLength with switching point = L + 48 mm (1.9 in)
28mm
7
(1
/64")
(1
42mm
21
/32")
4
2)
Keep in mind that the total length is extended by the plug connection.
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OPTISWITCH 4000 C - with transistor output29
Page 30
Supplement
30OPTISWITCH 4000 C - with transistor output
31763-EN-060830
Page 31
Supplement
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OPTISWITCH 4000 C - with transistor output31
Page 32
Subject to change without notice
31763-EN-060830
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