KROHNE 5015K User Manual

07.03.2003

Installation and operating instructions

BATCHFLUX 5015 K

Compact electromagnetic flowmeters

Please note!

Do not open the housing of the BATCHFLUX IFM 5015 K.

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 BATCHFLUX IFM 5015 K 5

Part A System installation and start-up 6 - 16

1 Installation in the pipeline 6 - 11

1.1 Important information 6

1.2 Suggestions for installation 7

1.3 Installation requirements 8-9

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 5015 K 10

1.5 Size of connections 11-12

1.5.1 Fastening with tie bolts 11

1.5.2 Fastening with tie bolts (option) 12

2 Electrical connection 13 - 14

2.1 Important information 13

2.2 Attachment plugs 13

2.3 Power supply and outputs 14

3 Start-up 15 - 16

3.1 Checking for availability 15

3.2 Factory settings 16

Part B IFC 015 signal converter 17 - 34

4 Operator control of signal converter with the HHT 010 17 - 27

4.1 Operator control concept 17

4.2 Operating and check elements 18

4.3 Function of keys 18 - 19

4.4 Table of settable functions 20 - 24

4.5 Error messages in measuring mode 25

4.6 Resetting totalizers and deleting error messages, RESET / QUIT menu 26

5 Description of functions 28 - 35

5.1 Full-scale range Q

5.2 Time constant 28

5.3 Low-flow cutoff 28

5.4 Display with HHT 010 29

5.5 Internal electronic totalizer 30

5.6 Current output I 30

5.7 Pulse output P 30 - 31

5.8 Status output S (option) 32

5.9 Language 32

5.10 Entry code 33

5.11 Primary head 33

5.12 User-definable unit 34

5.13 F/R mode, forward / reverse flow measurement 35

5.14 Characteristic of outputs 35

100%

Installation and operating instructions 2 BATCHFLUX

Part C Special applications, functional checks, and service 36 - 42

6 Special applications 36

6.1 RS 232 adapter and KROHNE software (option) 36

6.2 Operation via HHT 010 hand-held terminal (option) 36

7 Functional checks 37 - 39

7.1 Zero check with signal converter IFC 015 37

7.2 Test of measuring range Q, Fct. 2.1 38

7.3 Hardware information and error status, Fct. 2.2 39

8 Service 40 - 41

8.1 Important advice for removing the flowmeter from the pipeline – PLEASE NOTE 40

8.2 Removal from the pipe system 40

8.3 Removal of the electronics unit 41

8.4 Restart 41

9 Illustrations of printed circuit boards 42

Part D Technical Data, block diagram and measuring principle 43 - 49

10 Technical data 43 - 47

10.1 Flow during filling and fill volume 43

10.2 Flowmeters 43

10.3 Signal converter 44

10.4 Error limits at reference conditions 45

10.5 Dimensions and weights 46 - 47

10.6 Instrument nameplates 47

11 Block diagram 48

12 Measuring principle 49

Part E Annex 50 - 52

E1 Index 50 - 51 E2 Form to accompany returned device 52

Please note!

Do not open the housing of the BATCHFLUX IFM 5015 K.

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

BATCHFLUX

System description

The BATCHFLUX IFM 5015 K compact electromagnetic flowmeter is a precision instrument designed for the linear flow measurement of liquid products.

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 0.3 - 12 m/s.

Standards and approvals

BATCHFLUX IFM 5015 K with the IFC 015 signal converter meets the EU-EMC Directives and

•

bears the CE and 3A symbol.

The 3A approval accepts only adapters shown in Sect. 1.5.

•

All factories and production sequences are ISO 9001 certified.

•

/10” – 11/2” Q

can be set as a function of the meter size:

100%

= 0.0015 - 15 l/s

100%

Product liability and warranty

The compact BATCHFLUX IFM 5015 K electromagnetic flowmeter is designed exclusively for measuring the volumetric flowrate of electrically conductive, liquid process products.

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 BATCHFLUX IFM 5015 K flowmeters need to be returned to KROHNE, please note the information 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 BATCHFLUX

Functional description BATCHFLUX IFM 5015 K

The volume to be filled into the container is measured “in line“ by means of the electromagnetic flowmetering system. The batch controller closes the filling valve once the preset 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 signal into volume pulses that are intelligible to the batch controller. For a filling volume of 1000 ml, for example, this could be 10 pulses per ml; in other words, the batch controller switches the valve off after 1000 pulses have been received.

The influence of valve closing times and other dynamic factors can be corrected by the adaptive corrector of the batch controller.

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

Feed tank

(pressurized if liquid

contains CO2)

Flowmeter

BATCHFLUX

Valve

Container

bottle, tin, keg, paper or

plastic container

(pressurized if liquid

contains CO2)

e.g. 10 pulses per ml

pulses per volumes

valve control signal

on off

open valve

filling time t

Start command

when container is ready

for filling

close valve

External communication

(preselection,

measuring error correction)

Installation and operating instructions

BATCHFLUX

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 completed

•

filled at all times.

Direction of flow: the red 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 counter 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, see Section. 7.1, 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 10.2 “Limits“.

Please note!

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

Installation and operating instructions 6 BATCHFLUX

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.

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

Direction of flow The red 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).

Installation and operating instructions

BATCHFLUX

1.3 Installation requirements

Items supplied with flowmeter

BATCHFLUX IFM 5015 K 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 by customer.

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

its conical in/outlet.

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

/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

Requirements

Use in the food industry

The IFM 5015 K is specifically suitable for use in the food and beverage industry or similar sterile processes.

The IFM 5015 K is steam-resistant and can be pigged.

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.

• Install meter vertically or in a slope due to

On DN 15 ( BATCHFLUX with straight ceramic tube is available.

/2”) and DN 32 (11/4”), a

Installation and operating instructions 8 BATCHFLUX

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

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,

24 V 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 voltages. Therefore do not ground any other electrical device simultaneously with this conductor.

RF RF

Cu.

Installation and operating instructions

BATCHFLUX

1.4 Installation of the primary head

1.4.1 Device description

BATCHFLUX IFM 5015 K

•

4 Cover, signal converter 5 Primary head 8 Connector for power and pulse output (optionally: and status output) 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 5015 K

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 and passive pulse

•

output 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 BATCHFLUX

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

2.5

/10 6 25.5 30

/8 7 25.5 30

/8 12 25.5 30

/2 14 25.5 30

(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

on request

40 11/2 on request

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

-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

DN 2.5 - 15 / 1/10“ - 1/2“

DN 25 / 1“

A-A

DN 32-40 /

/4“-11/2“

Dimensions on request

Installation and operating instructions

BATCHFLUX

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

2.5

15 (0.55) (1.00) (1.18

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

(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 BATCHFLUX

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) Overvolta 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) Safet The compact flowmeters must be provided with an isolating facility.

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

2.2 Attachment plugs

Manufacturer Series and type Description

Binder Series 715 Moulded plug, straight or

Series 763 Integrally extruded plug

Hirschmann E-Series ELKA 4012 and

ELKA 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

Coninvers Series BC Moulded plug, straight

ge class:

y isolation:

ELWIKA 4012

and ELWIKA KV 4412

compact

angle-entry form

with cable in various lengths

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

Detail

Installation and operating instructions

BATCHFLUX

2.3 Power supply and outputs

Standard 4-pin connector M12x1 for 24 V DC power supply and passive pulse output

Pin Standard

Pin assignment

Pulse output passiv

ext.

max

The pulse output is galvanically isolated from the 24 V power supply.

Pulse output

•

See also Sect. 3.2 “factory settings“.

•

counters connected, allow for minimum counting interval: counter gate time [s]

•

pulses per m³, litres, US gallons or user-defined unit

•

> 10 Hz: - automatic, pulse width

- symmetrical 1:1

Status output

•

See also Sect. 3.2 “factory settings“.

•

+ 24 V

pulse output pulse output ⊥

ground

pulse output

≤ 30 V DC / ≤ 24V AC

≤ 20 mA

All operating data and functions are settable (see Sect. 6).

All data and functions are factory-set to your specifications.

Connection of electronic totalizers.

Digital pulse division. Interpulse period non-uniform, therefore if frequency meters or cycle

Pulse rate for Q = 100% max. 10 kHz, fixed or optionally in

Pulse width ≤ 10 Hz: 50, 100, 200 or 500 ms

All operating data and functions are settable (see Sect. 6).

All data and functions are factory-set to your specifications.

Can be set to signal direction, errors or trip points.

power

24 Volt DC

f21×

100%

1000

≥

100%

[Hz]P

Installation and operating instructions 14 BATCHFLUX

3 Start-up

Before powering the system, check that it has been correctly installed according to Sections 1 and 2.

The compact flowmeter is delivered ready for operational use. All operating data have been factory set in accordance with your specifications.

Power the unit, and the flowmeter will immediately start process flow measurement.

3.1 Check for availability

Please note!

Do not open the housing of the BATCHFLUX IFM 5015 K.

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.

The measurement status is signalled by the

•

light-emitting diodes (LED) below the cover of the converter housing (see amplifier board on right).

LED 1 LED 2 Function

flashing off in order flashing flashing overdriving

on flashing Fatal Error

(defective operating

parameter) off on defective hardware off off no supply voltage

or hardware

is defective

LED 2 LED 1

Refer to Section 6 for operator control.

•

Furthermore, external facilities (hand-held communicator HHT 010, PC, etc.) can be connected on the pc board of the control electronics via the IMoCom interface. This will enable precise checking of the correct mode of operation of the Batchflux IFM 5015 K.

All operating data can be set and stored by means of a personal computer via the IMoCom interface. The digital IMoCom interface allows the complete filling procedure to be graphically represented on the PC, thus providing visualization of system and valve properties.

Installation and operating instructions

BATCHFLUX

3.2 Factory settings

All operating data are factory-set according to your order specifications.

To facilitate easy and rapid initial start-up, pulse output is - unless specified otherwise set to process flow measurement in “2 flow directions“ so that the current flowrate is displayed and the volumetric flow counted independent of the direction of flow.

Table of standard factory settings

Function Setting

1.1 Full-scale range Q

1.2 Time constant 3 s, for S (option)

1.3 Low-flow cutoff SMU (do not change setting!)

1.4 Display

1.5 Current output I (NO HARDWARE !)

(function must be set to “OFF“!)

1.6 Pulse output P Function Pulse value Pulse width

1.7 Status output (NO HARDWARE !) (function must be set to “OFF“!)

3.1 Language for display only English (or other)

3.2 Flowmeter Size Flow direction (see arrow on primary head)

3.4 Entry code no

3.5 User-definable unit Liter/h

100%

The factory setting for the current and pulse outputs may occasionally cause measuring errors, particularly in the case of volume flow counting. For example, if pumps are switched off and a “backflow“ occurs that is not within the range of the low-flow cutoff (SMU), or if separate displays and counts are required for both flow directions. To avoid faulty measurements, therefore, it may be necessary to change the factory setting of some or all of the following functions:

low-flow cutoff SMU, Fct. 1.3

•

pulse output P, Fct. 1.6

•

see instrument nameplate

ON: 4 % OFF: 5 %

OFF

1 direction 1000 pulses/s automaticly

OFF

see instrument nameplate + direction

Installation and operating instructions 16 BATCHFLUX

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