KROHNE 5014C User Manual

18.10.2005

Installation and operating instructions

BATCHCONTROL 5014 C

Compact Electromagnetic Flowmeters with CANopen bus interface

Please note!

Do not open the housing of the BATCHCONTROL 5014C.

Danger of contamination with substances likely to destroy the moisture barrier of the electronic equipment (e.g. if CIP or SIP cleaned from the outside).

Therefore, please contact your KROHNE Service engineer before you open the housing.

Contents

System description 4 Standards and approvals 4 Product liability and warranty 4 Functional description BATCHCONTROL IFM 5014C 5

Part A System installation and start-up 6 - 15

1 Installation in the pipeline 6 - 12

1.1 Important information 6

1.2 Suggestions for installation 7

1.3 Installation requirements 8

1.3.1 Position of flange 9

1.3.2 Example: centering and sealing the primary head 9

1.3.3 Grounding 9

1.4 Installation of the primary head 10

1.4.1 Device description 10

1.4.2 Installation of the IFM 5014C 10

1.5 Size of connections 11 - 12

1.5.1 Fastening with tie bolts 11

1.5.2 Fastening with bolts (option) 12

2 Electrical connection 13 - 14

2.1 Important information 13

2.2 Attachment plugs 13

2.3 Power supply and CAN bus 14

2.4 Input and output 14

2.5 Block circuit diagram 14

3 Start-up 15

3.1 Checking for availability 15

3.2 Factory settings 15

Part B IFC 014 batch controller 16 - 20

4 Description of functions 16 - 20

4.1 Contact outputs 16

4.2 Voltage input 16

4.3 Contact input 16

4.4 CAN bus and parameter 16 - 17

4.5 Temperature sensors 17

4.6 Flow sensor 17

4.7 An example for a filling process 17 - 20

Part C Service 21

5 Illustrations of printed circuit boards 21

Part D Technical Data, block diagram and measuring principle 22 - 28

6 Technical data 22 - 26

6.1 Flow during filling and fill volume 22

6.2 Flowmeters 22

6.3 Signal converter 23

6.4 Error limits at reference conditions 24

6.5 Dimensions and weights 25 - 26

6.6 Instrument nameplates 26

7 Block diagram 27

Installation and operating instructions 2 BATCHCONTROL

8 Measuring principle 28

Part E Annex 29 - 47

E1 Index 29 E2 CAN parameter 30 - 45 E3 Form to accompany returned device 46

Please note!

Do not open the housing of the BATCHCONTROL IFM 5014C.

Danger of contamination with substances likely to destroy the moisture barrier of the electronic equipment (e.g. if CIP or SIP cleaned from the outside).

Therefore, please contact your KROHNE Service engineer before you open the housing.

Installation and operating instructions

BATCHCONTROL

3

System description

The BATCHCONTROL IFM 5014C compact electromagnetic flowmeter is a precision instrument designed for the linear flow measurement of liquid products and c ontrolling the filling process.

The products need to be electrically conductive: > 5 µS/cm (except for water) > 20 µS/cm (for water)

The full-scale range Q DN 2.5 – 40 and This is equivalent to a flow velocity of 0.2 - 12 m/s.

1

/10” – 11/2” Q

can be set as a function of the meter size:

100%

= 0.0015 - 15 l/s

100%

Standards and approvals

BATCHCONTROL IFM 5014C with the IFC014 signal converter meets the EU-EMC Directives

•

and bears the CE and 3A symbol. The 3A approval covers only the meter without adapter.

•

All factories and production sequences are ISO 9001 certified.

•

Product liability and warranty

The compact BATCHCONTROL IFM 5014C electromagnet ic flowmeter is des igned exclusivel y for measuring the volumetric flowrate of electrically conductive, liquid process produc ts.

The compact flowmeter is not suitable for use in hazardous areas. Other flowmeter series are available for such applications.

Responsibility as to suitability and intended use of this compact electromagnetic flowmeter rests solely with the operator.

Improper installation and operation of the flowmeters (systems) may lead to loss of warranty. In addition, the “General conditions of sale“ forming the basis of the purchase contract are

applicable. If BATCHCONTROL 5014C flowmeters need to be returned to KR OHNE, please note the infor-

mation given on the last-but-one page of these instructions. KROHNE regret that they cannot repair or check your flowmeter(s) unless these are accompanied by the completed form sheet.

Installation and operating instructions 4 BATCHCONTROL

Functional description BATCHCONTROL IFM 5014C

The volume to be filled into the container is measured “in line“ by means of the electromagnetic flowmetering system. The BATCHCONTROL closes the filling valve once the pres et filling volume has been reached. It is always the preset target volume that is filled into the container.

The signal converter converts the measured flowrate signa l into volume that are transfered to the integrated batch controller.

The influence of valve closing times and ot her dynamic factors can be corrected by the adaptive correction formalism of the BATCHCONTROL 5014C.

The use of state-of-the-art microprocessor electronics and the high-speed anal og/digital converter also enables changes in the flowrate to be sensed precisely. This technology ensures high reproducibility and long-term stability.

Installation and operating instructions

BATCHCONTROL

5

1

Part A System installation and start-up

1 Installation in the pipeline

1.1 Important information

The following recommendations should be observed to ensure proper functioning of the flowmeter – PLEASE NOTE.

Measuring tube must be filled

•

completely at all times. Direction of flow: the blue arrow on the

•

housing of the primary head must point in the direction of flow. If for structural reasons the flowmeter can only be installed invers to the direction of flow, the direction of flow measurement can be reprogrammed.

Stud bolts and nuts: to fit, make sure

•

there is sufficient room next to the pipe flanges.

Vibration: support the pipeline on both

•

sides of the flowmeter. Vibration level to IEC 068-2-34: below 2,2g in the 20 - 2000 Hz frequency range.

Radiant heat: avoid e.g. from hot product

•

tanks, insulate if necessary. Avoid strong electromagnetic fields

•

in vicinity of flowmeter.

Straight Inlet run ≥ 5 x DN and straight

•

outlet run ≥ 2 x DN, measured from the electrode axis (DN = meter size).

Vortex or corkscrew flow: increase

•

length of inlet and outlet runs or install flow straighteners.

Mixing different process liquids: install

•

flowmeter upstream of mixing point or at an adequate distance downstream, minimum of 30 x DN (DN = meter size), otherwise display may be unsteady.

Plastic pipes and internally coated metal

•

pipes: grounding rings required, see “Grounding“, Section 1.3.3.

Heat-insulated pipelines: do not insulate

•

flowmeter. Zero setting: not required. For checking

•

purpose, it should be possible to set “zero“ flow velocity in the completely filled measuring tube. Shutoff valves should therefore be provided either downstream or upstream and downstream of the flowmeter.

Ambient temperature

•

-25°C to +60°C

Process temperature

•

max. 140 °C Transport and storage temperature

•

-25°C to +60°C

Limits imposed by the material used for the measuring tube for process temperature, thermal shock limit, pressure and vacuum, see Section D page 22.

Please note!

The ceramic measuring tube must not contac t metal parts (flange, pipeline). This can destroy the flowmeter!

Installation and operating instructions 6 BATCHCONTROL

A

1.2 Suggestions for installation

To avoid measuring errors due to air inclusion and vacuum, please observe the following:

Highest point of pipe run

(Air bubbles collect in measuring tube - faulty measurements!)

Preferred locations

downpipe

(open discharge)

void draining or partial filling of the measuring tube. Faulty measurements.

1

Pumps Do not install flowmeter on pump suction side

Open feed or discharge Install meter in low section of pipe

open discharge

Selecting the installation location Location and position as required, but electrode axis (X – – – – X must be approximately horizontal in a horizontal pipe run.

Horizontal pipe run

Install in slightly descending pipe section to prevent air from collecting, so avoiding faulty measurements and that meter can drain.

Control and shutoff valves: always install behind the flowmeter

x

Direction of flow The blue arrow on the primary head housing must point in the flow direction.

On high-temperature pipes and

where process temperatures exceed 100 °C, provide facilities to

compensate for longitudinal expansion on heat-up of the pipeline. Use flexible pipe elements (e.g. elbows).

x

Installation and operating instructions

BATCHCONTROL

7

1

1.3 Installation requirements

Items supplied with flowmeter

BATCHCONTROL IFM 5014C compact

•

flowmeter in the version as ordered Installation and operating instructions,

•

as agreed Certificate of system calibration data

•

(as agreed)

Excluding fitting accessories. Stud bolts, gaskets, etc., to be provided b y customer.

All operating data and function values are factory set according to your order specifications.

Requirements Use in the food industry

The IFM 5014C is specifically suitable for us e in the food and beverage industry or similar sterile processes.

The IFM 5014C is steam-resistant. The measuring tube can be SIP or CIP

cleaned when in installed condition. During the cleaning the meter(s) must be switched off to maintain the reliability of the unit(s).

• Operating pressure, type, and space

between pipe flanges: see Table.

• Tighten stud bolts uniformly down to the

metal stop in diagonally opposed sequence. See Table for type and number of stud bolts.

• Ins tall meter vertically or in a slope due to

its conical in/outlet. On DN 15 (1/2”) and DN 32 (11/4” ) a BATCHCONTROL with straight ceramic tube is avaible.

DIN 2501

and JIS pipe flanges Nm kpm ft × lbf

DN 2.5 DN 4 DN 6 1/4" 51.8 mm (2.04") 4 x M12 10 1.0 7.2 DN 10 3/8" 51.8 mm (2.04") 4 x M12 10 1.0 7.2 DN 15 1/2" 51.8 mm (2.04") 4 x M12 10 1.0 7.2 DN 25 1" 58.0 mm (2.28") 4 x M12 10 1.0 7.2 DN 32 11/4“ 83.0 mm (3.27“) 4 xM16 43 4.3 31.0 DN 40 1 1/2" 83.0 mm (3.27") 4 x M16 43 4.3 31.0

ANSI B 16.5 Space between Bolts Max torque

1

/10" 51.8 mm (2.04") 4 x M12 10 1.0 7.2 /8" 51.8 mm (2.04") 4 x M12 10 1.0 7.2

Installation and operating instructions 8 BATCHCONTROL

y

R

1.3.1 Position of flanges

Install flowmeter in line with the pipe axis. Pipe flange faces must be parallel to each other, max. allowable deviation: L

– L

max

1.3.2 Example: centering and sealing

The primary head is centered between the pipe flanges with the aid of the precise geometric fitting (guide collar on primary head).

Detail drawings see Sect. 1.5.

≤ 0.5 mm ≤ 0.02"

min

the primary head

1.3.3 Grounding

V

R

FE

FE Functional ground, wire > 4 mm R Pipeline RF Pipe flanges V Interconnecting wires, bolted to the housing

Grounding is carried out via the functional ground that is connected to the U-clamp terminal (9). See also Section 2 “Electrical connection“.

When connected to functional extra-low voltages,

24V DC, protective separation (PELV) must be ensured (VDE 0100/VDE 0106 or IEC 364/IEC 536).

All flowmeters must be properly

•

grounded. The grounding wire should not

•

transmit any interference voltage. Therefore do not ground any other electrical device simultaneousl with this conductor.

RF RF

V

2

Cu.

1

Installation and operating instructions

BATCHCONTROL

9

1

1.4 Installation of the primary head

1.4.1 Device description

BATCHCONTROL IFM 5014C

•

4 Cover, signal converter 5 Primary head 7 Connector for the six in-/outputs 8 Connector for power and CAN Bus 9 U-clamp terminal for functional ground 10 Fastening screws for cover 11 Locating collar, primary head

Accessories from system manufacturer

•

12 O-ring gasket 13 Special pipe flange 14 Stud bolt with lock washer, plain washer and nut

To facilitate servicing of the primary head, please note the following points:

It must be possible to shut off the flow

•

through the pipeline upsteam of the primary head (provide shutoff valve),

Drain the pipe system before removing the

•

primary head (provide drain valve), Support the pipeline on both sides of the

•

flowmeter when located in a long, freely suspended section to facilitate removal of the primary head.

1.4.2 Installation of the IFM 5014C

Position gaskets (12) in the pipe flanges.

•

Type and location of gaskets as specified

•

by the manufacturer of the filling machine (see Sect. 1.3.2 “Centering of the primary head”).

Insert primary head (5) between the pipe

•

flanges (13) in line with the pipe axis. For spacing and location of the pipe

•

flanges, see Sect. 1.3 “Position of flanges”. Press pipe flanges against flowmeter.

•

Centering ring of pipe flanges must snap into place in the guide collar (11) of the primary head.

Insert stud bolts (14) with washers into the

•

holes in the pipe flanges. Fit nuts to stud bolts with lock washer.

Tighten stud bolts and nuts down to the

•

metal stop symmetrically. Check all bolts after starting up the pipe system, and retighten when any leaks show.

Connect ground conductor to U-clamp

•

terminal (9). Connect power supply, CAN bus and

•

outputs to connector plugs (7, 8) on signal converter housing (4).

See Section 2.2 and 2.3 for details of electrical connection.

Installation and operating instructions 10 BATCHCONTROL

A

1.5 Size of connections

1.5.1 Fastening with tie bolts

All dimensions in mm (inches)

Flange-material: AISI 300 series O-ring material: 3A standard 18-03

Meter size Centering device, pipe connection O-Ring Dimensions

DN inches d

1

2.5

/10 6 25.5 30

1

4

/8 7 25.5 30

1

6

/4

3

10

/8 12 25.5 30

1

15

/2 14 25.5 30

i

(0.24) (1.00) (1.18 (0.28) (1.00) (1.18

9 25.5 30

(0.35) (1.00) (1.18 (0.47) (1.00) (1.18

(0.55) (1.00) (1.18 25 1 26 37.5 71.3 (1.02) (1.48) (2.81

1

32

1

/

4

on request

40 11/2 on request

DN 2.5 - 15 / 1/10“ - 1/2“

D1 D2 h 75 Shore k d

1.5

-0.05/-0.15

) (0.06

-0.002/-0.006

1.5 ) (0.06

-0.002/-0.006

1.5 ) (0.06

-0.002/-0.006

1.5 ) (0.06

-0.002/-0.006

1.5 ) (0.06

-0.002/-0.006

2

-0.1

) (0.08

–0.004

on request 60 8.5

-0.05/-0.15

) on request (2.36) (0.33)

-0.002/-0.006

on request 60 8.5

) on request (2.36) (0.33)

-0.002/-0.006

on request 60 8.5

) on request (2.36) (0.33)

-0.002/-0.006

on request 60 8.5

) on request (2.36) (0.33)

-0.002/-0.006

Ø 16×5 60 8.5

) (Ø 0.47×0.20) (2.36) (0.33)

-0.002/-0.006

Ø 28×5 80 8.5

+0.1

) (Ø 1.10×0.20) (3.15) (0.33)

+0.04

1

DN 25 / 1“

A-A

Installation and operating instructions

DN 32-40 /

1

/4“-11/2“

Dimensions on request

BATCHCONTROL

11

1

1.5.2 Fastening with bolts (option) All dimensions in mm (inches)

* Flange-material : AISI 300 series

O-ring material : 3A standard 18-03

Meter size Centering device, pipe connection O-ring Screw thread (option)

gaskets 2× M4 4× M6

inches

DN

1

2.5

1

4

1

6

3

10

1

15 (0.55) (1.00) (1.18

d

D1 D2 h 75 Shore k d k d

/10 6 25.5 30

/8 7 25.5 30

/4 9 25.5 30

/8 12 25.5 30

/2 14 25.5 30

i

(0.24) (1.00) (1.18 (0.28) (1.00) (1.18 (0.35) (1.00) (1.18 (0.47) (1.00) (1.18

-0.05/-0.15

-0.002/-0.006

-0.05/-0.15

-0.002/-0.006

-0.05/-0.15

-0.002/-0.006

-0.05/-0.15

-0.002/-0.006

-0.05/-0.15

-0.002/-0.006

1.5 ) (0.06

on request 60 8.5 56 6.4

-0.05/-0.15

) on request (2.36) (0.33) (2.20) (0.25)

-0.002/-0.006

on request 60 8.5 56 6.4

) on request (2.36) (0.33) (2.20) (0.25)

-0.002/-0.006

on request 60 8.5 56 6.4

) on request (2.36) (0.33) (2.20) (0.25)

-0.002/-0.006

on request 60 8.5 56 6.4

) on request (2.36) (0.33) (2.20) (0.25)

-0.002/-0.006

Ø 16×5

)

(Ø 0.47×0.20)

60 8.5 56 6.4

*

(2.36) (0.33) (2.20) (0.25)

*

Installation and operating instructions 12 BATCHCONTROL

2 Electrical connection

2.1 Important information

Be sure to take note of the following information in order to ensure proper functioning of the signal converter.

Please note:

1) Ov ervolta In conformity with VDE 0120, equivalent to IEC 664, the compact flowmeters are designed for overvoltage category III in the supply circuits and overvoltage category II in the output circuits.

2) Safety isolation: The compact flowmeters must be provided with an isolating facility.

Electrical connection and repairs may only be carried out by qualified personnel.

ge class:

2.2 Attachment plugs

Manufacturer Series and type Description

Binder Series 715 Moulded plug, straight or

angle-entry form

Series 763 Integrally extruded plug

with cable in various

lengths Hirschmann E-Series ELKA 4012 and

ELWIKA 4012

ELKA KV 4412

and ELWIKA KV

4412 Lumberg RK-Series RKC and RKCW Moulded plug, straight or

RKT and RKWG Integrally extruded plug

Amphenol Series C 164 P Moulded plug, straight or Series C 164 P

compact Coninvers Series BC Moulded plug, straight

Moulded plug, straight or angle-entry form Integrally extruded plug with cable in various lengths

angle-entry form with cable in various

lengths angle-entry form

Integrally extruded plug with cable in various lengths

form, especially suitable for high-interference environments (keyword: EMC)

Protect the flowmeter from direct radiant

•

heat (e.g. hot-product tanks), insulate if necessary.

Do not expose flowmeter to intense

•

vibration. If necessary, support the pipeline to the right and left of the flowmeter. Level of vibration in accordance with IEC 068-2-34: below 2.2g in the 20 2000 Hz frequency range.

Note information given on the instrument

•

nameplate, voltage. The FE functional ground for the supply

•

power should for measurement reasons be connected to the separate U-clamp terminal on the signal converter housing.

When connected to a functional extra-

•

low voltage of 24 V DC, protective separation (PELV) must be ensured (VDE 0100 / VDE 0106 or IEC 364 / IEC 536 or equivalent national regulations)..

Pin-assignment and alignment of cable entry body

Installation and operating instructions

BATCHCONTROL

13

2

2.3 Power supply and CAN bus

5-pin connector M12x1 for 24V DC power supply and CAN bus

Pin Description 1 ground CAN bus

2 +24 V power 3 ground 4 CAN high level 5 CAN low lev el

Pin assignment

2.4 Input and output

8-pin connector M12x1 for 24V DC power supply and input / output signals

Pin Description 1 input / output 1

2 input / output 2 3 input / output 3 4 input / output 4 5 input / output 5 6 input / output 6 7 +24 V power 8 ground

Pin assignment

2.5 Block circuit diagram

The following picture shows the block circuit diagram of the BATCHCONTROL 5014C:

The individual functions of inputs and outputs are described in detail in the following chapter.

Installation and operating instructions 14 BATCHCONTROL