Page 1
Installation instructions
VARIFLUX 6000
Electromagnetic flowmeters
GR
How to use these Instructions
The flowmeters are supplied ready for operation.
The flow sensor must be installed in the pipeline as described in the installation
instructions inside the packing of the primary head.
– Installation in the pipeline Pages 4-5+7-8
– Grounding Page 9
Power the flowmeter. THAT’S ALL.The system is operative.
● Flow sensors
● Compact flowmeters
Variable area flowmeters
Vor tex flowmeters
Flow controllers
Electromagnetic flowmeters
Ultrasonic flowmeters
Mass flowmeters
Level measuring instruments
Communications technology
Engineering systems & solutions
Switches, counters, displays and recorders
Heat metering
Pressure and temperature
DIN A4: 7.02143.32.00
©
KROHNE 04/2003 US size: 7.02143.72.00
Page 2
Contents
System description ....................................................................................................................... 2
Product liability and warranty ...................................................................................................... 2
Standards and approvals.............................................................................................................. 3
Items included with supply........................................................................................................... 3
1
Important information for installation: PLEASE NOTE ! ................................................ 4
2
Suggestions for installation...............................................................................................5
3
Instrument nameplate ........................................................................................................6
4
Versions ..............................................................................................................................6
5
Installation in the pipeline..................................................................................................7
6
Limits ...................................................................................................................................8
7
Grounding ...........................................................................................................................8
8
Replacement of the separate flow sensors ...................................................................... 9
9
Replacement of l-shaped gaskets with adapters ........................................................... 10
10 Spare parts and order numbers ......................................................................................10
11 Technical data................................................................................................................... 11
12 Dimensions and weights.................................................................................................. 12
If you need to return flowmeters for testing or repair to KROHNE ......................................... 15
VARIFLUX electromagnetic flowmeters are precision measuring instruments designed for the
linear flow measurement of process liquids.
The process liquids must be electrically conductive: ≥ 5 µS/cm
≥ 20 µS/cm for demineralized cold water
The full-scale range Q
DN 2.5 - 150 / 1/10” - 6” Q
This is equivalent to a flow velocity of 0.3 - 12 m/s, or 1 - 40 ft/s.
can be set as a function of the meter size:
100%
VARIFLUX electromagnetic flowmeters are designed solely for measuring the volumetric flowrate
of electrically conductive, liquid process products.
Special codes and regulations apply to their use in hazardous locations, and these are referred to
in the special “EEx” installation and operating instructions (supplied only with hazardous-duty
equipment).
Please note: Flowmeters for use in hazardous locations (EEx) have different dimensions and
changed constructions.
Responsibility as to suitability and intended use of these electromagnetic flowmeters 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 VARIFLUX flowmeters need to be returned to Krohne, please note the information given on the
last-but-one page of this manual. Krohne regret that they cannot repair or check your
flowmeter(s) unless accompanied by the completed form sheet.
System description
= 0.01 - 763 m3/hr = 0.02 - 3361 US Gal/min
100%
Product liability and warranty
2 Installation instructions VARIFLUX 6000
Page 3
Standards and approvals
Please refer to the installation and operating instructions for the signal converter.
The VARIFLUX flowmeters are approved to 3A and to EHDEG for the
adapters to DIN 11850, ISO 2037 and DIN 11864-2a.
Items included with supply
VARIFLUX 6000 flow sensor
• flow sensor in the size as ordered • compact flowmeter in the size as ordered
• certificate of calibration data • certificate of calibration data
• installation instructions • installation instructions
Items included with supply
mounted adapter with fitted L-shaped gaskets D1 (counterparts for the pipeline).
Available meter size / Types and sizes of connections
Meter size Available types and sizes of connections
DIN
DN mm inch mm mm (inch) mm mm (inch) mm (inch) mm (inch) mm mm
2.5 1/10 DN 10 10.0 (0.39) DN 10 - 10.0 (0.39) - - -
4 1/8 DN 10 10.0 (0.39) DN 10 - 10.0 (0.39) - - -
6 1/4 DN 10 10.0 (0.39) DN 10 - 10.0 (0.39) - - -
10 3/8 DN 10 10.0 (0.39) DN 10 - 10.0 (0.39) - - -
15 1/2 DN 15 15.0 (0.59) DN 15 - 15.0 (0.59) - - -
25 1 DN 25 22.6 (0.89) DN 25 25 (1) 22.6 (0.89) 22.6 (0.89) 22.6 DN 25
40 1 1/2 DN 40 37.6 (1.48) DN 40 40 (11/2) 37.6 (1.48) 37.6 (1.48) 37.6 DN 40
50 2 DN 50 48.6 (1.91) DN 50 50 (2) 48.6 (1.91) 48.6 (1.91) 48.6 DN 50
65 2 1/2 DN 65 60.3 (2.37) DN 65 65 (21/2) 60.3 (2.37) 60.3 (2.37) 60.3 DN 65
80 3 DN 80 72.9 (2.87) DN 80 80 (3) 72.9 (2.87) 72.9 (2.87) 72.9 DN 80
100 4 DN 100 97.6 (3.84) DN 100 100 (4) 97.6 (3.84) 97.6 (3.84) 97.6 DN 100
125 5 DN 125 110.3 (4.34) DN 125 - 110.3 (4.34) - - DN 125
150 6 DN 150 135.7 (5.34) DN 150 - 135.7 (5.34) - - DN 150
Weld on to … Screwed to … Clamp joint to … Flanged to
11850
ISO 2037 DIN 11851
(dairy screw)
VARIFLUX 6010 K, VARIFLUX 6020 K and
VARIFLUX 6080 K compact flowmeters
• installation and operating instructions for the
signal converter
SMS
1145
ISO 2852 TRI-
CLOVER
DIN
32676
11864-2a
DIN
Installation instructions VARIFLUX 6000 3
Page 4
1 Important information for installation: PLEASE NOTE !
• Handling
Do not lift flowmeter by the signal converter
housing or the terminal box.
Do not set flowmeter down on signal converter
housing or terminal box.
PLEASE NOTE: the temperature limits for storage and transport, see below.
• Use only solventless detergents to clean the signal converter housing (polycarbonate).
• Temperatures
Refer to Section 11 “Limits” for operating pressure and vacuum load based on flange
standards and type of tube liner.
Ambient temperature Process temperature
Compact systems -25 to +60 °C (-13 to +140 °F) -20 to + 60 °C (-4 to +140 °F)
-25 to +40 °C (-13 to +104 °F) -20 to +140 °C (-4 to +284 °F)
VARIFLUX 6000 -25 to +60 °C (-13 to +140 °F) -20 to + 60 °C (-4 to +140 °F)
-25 to +40 °C (-13 to +104 °F) -20 to +140 °C (-4 to +284 °F)
• Location and position as required,
but electrode axis
X – • – • – • – X
must be approximately horizontal in a horizontal pipe run.
Y terminal box or converter housing
• Measuring tube must be completely filled at all times.
• Direction of flow is arbitrary. Arrow on flowmeter can normally be ignored. For exceptions,
refer to Section “Factory settings” in the installation and operating instructions for the signal
converter.
• 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 compact flowmeter.
Level of vibration in conformity with IEC 068-2-34: 20-500 Hz, random / 2g runs / 30 minutes /
x, y, z directions.
• Do not expose to direct sunlight, fit a sunshade if necessary, not included with flowmeter,
to be provided by customer.
4 Installation instructions VARIFLUX 6000
Page 5
• Strong electromagnetic fields, avoid in vicinity of flowmeter
• Straight inlet run minimum of 5 × DN and outlet run minimum of 2 × DN,
(DN = meter size), measured from the electrode axis.
• Vortex and corkscrew flow: increase length of inlet and outlet runs or install flow
conditioners.
• Mixing different process liquids: install flowmeter upstream of mixing point or at an
adequate distance downstream (minimum of 30 × DN), otherwise display may be unsteady.
• Insulated pipeline: do not insulate flowmeter.
• Zero setting not necessary. To check, it should be possible to set “zero” flow velocity in the
completely filled measuring tube. Shutoff valves should therefore be provided either
downstream of the flowmeter or upstream and downstream of the flowmeter.
2 Suggestions for installation
To avoid measuring errors due to gas/air inclusion or to pipe running empty, please observe the
following:
Highest point of pipe run Downpipe over 5 m (16 ft) length
(Air bubbles collect in measuring
tube - faulty measurements!) flowmeter.
Install air valve ✇ downstream of
Preferred
locations
Downpipe
“Zero” flow
velocity.
Line drained.
Faulty
measurements!
Long pipeline
Always install control and shutoff valves
downstream of flowmeter.
Horizontal pipe run
Install in slightly inclining pipe section. If not
possible, assure adequate velocity to prevent
air, gas or vapour from collecting in upper
part of flow tube.
Pumps
Open feed or discharge Never install flowmeter on pump suction side.
Install meter in low section of pipe.
open discharge
Installation instructions VARIFLUX 6000 5
Page 6
3 Instrument nameplate
VARIFLUX 6000
separate flow sensor
Series No.
Flow sensor
constant
Meter size
DN in mm and
inch equivalent
Liner
PFA
Type designation
Electrode material
See Table
6000
Flange pressure rating
or flange class
Magnetic field frequency
(here 1/6 of power frequency)
Electrode materials
HB Hastelloy B2
HC Hastelloy C4
PT Platinum
TA Tantalum
TI Titanium
V4A Stainless steel 1.4571 / SS 316-Ti or
Stainless steel 1.4401 / SS 316L
Instrument nameplate for VARIFLUX 6000 compact flowmeters
see installation and operating instructions for the signal converter.
4 Versions
Tag No.
Protection category
to IEC 529/EN 60529
Insulation class
of field coils
VARIFLUX 6000 Separate flow sensor electrically connected to the signal
converter by signal and field current cables.
VARIFLUX 6010 K Compact flowmeter (K), IFC 010 K or IFC 020 K signal converter mounted
VARIFLUX 6020 K
direct on the flow sensor.
VARIFLUX 6080 K Compact flowmeter (K), IFC 090 K signal converter mounted direct
on the flow sensor.
Versions for hazardous locations
VARIFLUX 6000 and VARIFLUX 6080 K are approved as electrical equipment to the harmonized
European Standards and to Factory Mutual (FM).
Test certificate, certificate of conformity and wiring instructions for these devices are attached to
the “EEx” installation instructions, provided only with hazardous-duty equipment.
Please note: Flowmeters for use in hazardous locations (EEx) have different dimensions and
changed constructions.
6 Installation instructions VARIFLUX 6000
Page 7
5 Installation in the pipeline
• Installation material not included, to be provided by customer (stud bolts,
nuts, gaskets, etc.)
• Pipe connections, operating temperature and pressure:
refer to tables on “Limits” in Section 6.
• Fitting dimension
see Sect. 12 “Dimensions and weights”;
• High-temperature pipelines
Where process temperatures exceed 100 °C/212 °F, provide for facilities to compensate for
longitudinal expansion on heat-up of the pipeline.
For short pipelines use resilient gaskets and for long pipelines install flexible pipe elements
(e.g. elbows).
• Position of connections
Install flowmeter in line with the pipe axis. Pipe
connections must be parallel to each other, max.
permissible deviation:
- L
L
max
≤ 0.5 mm
min
≤ 0.02’’
• Torques
For flanged instruments
to DIN 11864-2a
Tighten down stud bolts and nuts
with max. torque:
32 Nm ~ 3.2 kpm ~ 23.5 ft x lbf
For all other connections
Tighten down to metal stop.
Installation instructions VARIFLUX 6000 7
Page 8
6 Limits
Pressure rating
Aseptic weld on for pipes * *
to DIN 11850
Aseptic weld on for pipes
to ISO 2037
Dairy screw to DIN 11851
Screwed to SMS 1145
Flanges to DIN 11864-2A
Clamp joint to ISO 2852
Clamp joint to DIN 32676 * *
Clamp joint to TRI-CLOVER
Vacuum load
pressure ratings
mm inch
DN 10* - 40 – PN 40 – 40 ( 580) 40 ( 580) 40 (580) 40 (580)
DN 50 - 80 – PN 25 – 25 (360) 25 (360) 25 (360) 25 (360)
DN 100 – PN 16 – 16 (230) 16 (230) 16 (230) 16 (230)
DN 125 - 150 – PN 10 – 10 (145) 10 (145) 10 (145) 10 (145)
12* - 37.6 0.47* - 1.48 PN 40 580 psig 40 (580) 40 (580) 40 (580) 40 (580)
48.6 - 72.9 1.91 - 2.87 PN 25 360 psig 25 (360) 25 (360) 25 (360) 25 (360)
97.6 3.84 PN 16 232 psig 16 (230) 16 (230) 16 (230) 16 (230)
110.3 - 135.7 4.34 - 5.34 PN 10 145 psig 10 (145) 10 (145) 10 (145) 10 (145)
DN 10* - 40 – PN 40 – 40 ( 580) 40 ( 580) 40 (580) 40 (580)
DN 50 - 80 – PN 25 – 25 (360) 25 (360) 25 (360) 25 (360)
DN 100 – PN 16 – 16 (230) 16 (230) 16 (230) 16 (230)
DN 125 - 150 – PN 10 – 10 (145) 10 (145) 10 (145) 10 (145)
25 - 100 – PN 6 – 6 ( 90) 6 ( 90) 6 ( 90) 6 ( 90)
DN 25 - 40 – PN 40 – 40 (580) 40 (580) 40 (580) 40 (580)
DN 50 - 80 – PN 25 – 25 (360) 25 (360) 25 (360) 25 (360)
DN 100 – PN 16 – 16 (230) 16 (230) 16 (230) 16 (230)
DN 125 - 150 – PN 10 – 10 (145) 10 (145) 10 (145) 10 (145)
12* - 51 1½” - 2.0” PN 16 232 psig 16 (230) 16 (230) 16 (230) – –
63.5 - 76.1 2½” - 3.0” PN 10 145 psig 10 (145) 10 (145) 10 (145) – –
100 4” PN 8 115 psig 8 (115) 8 (115) 8 (115) – –
125 - 150 5” - 6” PN 5 72 paig 5 ( 72) 5 ( 72) 5 ( 72) – –
DN 25 - 50 – PN 16 – 16 (230) 16 (230) 16 (230) 16 (230)
DN 65 - 100 – PN 10 – 10 (145) 10 (145) 10 (145) 10 (145)
25 - 80 1” - 3” PN 20 280 psig 20.5 (295) 20.5 (295) 20.5 (295) – –
100 4” PN 12 174 psig 13.8 (200) 13.8 (200) 13.8 (200) – –
all versions and sizes all versions and 0 mbar abs. (0 psia)
of connections
Max. operating pressure in bar (psig) at product temperature of … Size of connections Type of connections
< 40 °C
(< 104 °F)
< 100 °C
(< 212 °F)
* for meter size size DN 2.5 - 10 / 1/10” - 3/8”
** max. temperature are 150 °C (302 °F)
7 Grounding
< 120 °C
(< 248 °F)
< 140 °C
(< 284 °F)
• Warning: All flowmeters must be properly grounded to avoid personnel shock hazard.
• The ground conductor should not transmit any interference voltages, therefore do not ground
any other electrical devices together with this conductor.
VARIFLUX 6000 compact systems
Supply power > 50 V AC
• Grounding is via the PE protective ground conductor incorporated in the power supply
cable, see also Section “Connection to power” in the installation and operating instructions for
the signal converter.
• EXCEPTION: Do not connect up the PE protective ground conductor in the terminal box
if e.g. compact units are operated in the proximity of electric furnaces, electrolysis plants, etc.,
and large potential differences occur in the pipeline system. An FE functional ground must
simultaneously take over the function of the protective conductor (combined protective /
functional ground). Refer to appropriate national codes for specific requirements for this type
of installation, which may require the addition of a ground fault detection circuit interrupter.
Supply power 24 V AC or DC
• Protective separation (PELV) must be ensured (VDE 0100 / VDE 0106 or IEC 364 / IEC 536 or
equivalent national regulations).
• An FE functional ground conductor must be connected for measurement reasons.
8 Installation instructions VARIFLUX 6000
Page 9
VARIFLUX 6000 separate flow sensor with terminal box
• A functional ground FE must always be connected.
• Signal converters with a field power supply of > 125 mA / > 60 V:
Because of the higher field current from the signal converter, a PE protective conductor
must be connected to the VARIFLUX 6000 flow sensor, see grounding diagrams.
Grounding diagram
Flowmeter with adapters
A
AF
C
D1
D2
FE
HF
P
PC
PE
Adapter complete, ready assembled
Adapter flange
Adapter connection
L-shaped gasket
Gaskets not included in supply, to be provided by customer
Functional ground, wire ≥ 4 mm
2
Cu, (10 AWG).
Housing flange for adapter
Pipeline
Pipe connection not included in supply, to be provided by customer
Protective conductor required if the VARIFLUX 6000 is operated with a signal converter
that supplies a field current of > 125 mA / > 60 V. Wire ≥ 4mm
2
Cu (10 AWG), not included
with flowmeter, to be provided by customer
Y
Signal converter or connection box
8 Replacement of the separate flow sensors
Switch off power source before commencing work !
1) Note down terminal assignment before dismantling the “old” flow sensor.
2) Install the new flow sensor as described in the supplied installation instructions.
3) Make electrical connection at the signal converter as described in the installation and
operating instructions for the signal converter.
4) Specific calibration data are defined during factory calibration for each flow sensor, which are
indicated on the instrument nameplate.
This includes the primary constant GK and the magnetic field frequency.
These data need to be reset in the signal converter.
5) If the size of flow sensor is also different from the old one, the full-scale range Q
meter size will need to be reset.
6) After resetting the signal converter, carry out a zero point check.
7) If necessary, reset the internal electronic totalizer of the signal converter.
100%
and the
Installation instructions VARIFLUX 6000 9
Page 10
9 Replacement of L-shaped gaskets with adapters
• Unscrew bolts (4) of the adapters (3).
• Remove the flowmeter (1) from the pipeline.
• Remove the L-shaped gaskets (2), new ones see spare parts in Sect. 10.
• Apply grease to new gaskets (Paraliq GTE 703, Silubin or similar) and
insert the new L-shaped gaskets in the adapers
• Slide the flowmeter (1) between the adapers and tighten bolts (4) down to metal stop.
4 8 5 4
3 2 1 3 7 1 6 2 3 1 2 3
1
Flow sensor
2
L-shaped gasket
3
Adapter
4
Srews for adapter
5
Connecting socket for signal converter (compact system)
or for connection box (separate version)
6
Field coils
7
Flow electrodes
rd
8
3
electrode for measurement of empty pipe (preparation for future developments)
10 Spare parts and order numbers
Gasket material
EPDM
Silicone
Meter size
DN mm inch
DN 2.5 - 10 1/10 - 3/8 DIN XN 99 03 041 0
DN 15
DN 2.5 - 10 1/10 - 3/8 ISO XN 99 03 051 0
DN 15
DN 25 1 DIN / ISO / SMS XN 99 03 061 0
DN 40 11/2 DIN / ISO / SMS XN 99 03 062 0
DN 50 2 DIN / ISO / SMS XN 99 03 063 0
DN 65 21/2 DIN / ISO / SMS XN 99 03 064 0
DN 80 3 DIN / ISO / SMS XN 99 03 065 0
DN 100 4 DIN / ISO / SMS XN 99 03 066 0
DN 125 5 DIN / ISO XN 99 03 067 0
DN 150 6 DIN / ISO XN 99 03 068 0
DN 2.5 - 10 1/10 - 3/8 DIN XN 99 03 080 0
DN 15
DN 25 1 DIN / ISO / SMS XN 99 03 082 0
DN 40 11/2 DIN / ISO / SMS XN 99 03 083 0
DN 50 2 DIN / ISO / SMS XN 99 03 084 0
DN 65 21/2 DIN / ISO / SMS XN 99 03 085 0
DN 80 3 DIN / ISO / SMS XN 99 03 086 0
DN 100 4 DIN / ISO / SMS XN 99 03 087 0
DN 125 5 DIN / ISO XN 99 03 088 0
DN 150 6 DIN / ISO XN 99 03 089 0
1
/2 DIN XN 99 03 042 0
1
/2 ISO XN 99 03 052 0
1
/2 DIN XN 99 03 081 0
Sanitary connection to … Order No.
10 Installation instructions VARIFLUX 6000
Page 11
11 Technical data
Size/type
Available connections
Electrical conductivity
Ambient temperature
Max. permissible operating data
DN 2.5 – 150 and
see page 3
≥ 5 µS/cm (≥ 20 µS/cm for demineralized water)
– 25 to + 60°C – 13 to + 140°C
1
/10” – 6”
Operating pressure / product temperature see table “Limits” in Sect. 6
Vacuum load 0 mbar abs. / 0 psia
Insulation class of field coils
Electrode design
H
permanently fitted (≥ DN 25 / ≥ 1” surface
polished)
Power for field coils
Protection category (IEC 529/EN 60 529)
Materials
> 60 V from signal converter
IP 67, equivalent to NEMA 6
Measuring tube stainless steel 1.4301
clear, virgin PFA, FDA-approved
Liner
DN 2.5 - 10 /
DN 15 - 150 /
Electrodes
1
/10” - 3/8” reinforced with sintered metal bearing bush
1
/2” - 6” reinforced with stainless steel mesh
Standard Hastelloy C4
Special versions:
Connections
stainless steel 1.4404/316L-AISI
L-shaped gaskets
≤ DN 15 / ½’’
≥ DN 25 / 1’’
Hastelloy B2, stainless steel 1.4571/316 Ti-AISI,
titanium, tantalum, platinum
stainless steel 1.4401/316L, titanium
Standard EPDM
Option Silicone or FKM
Housing
DN 2.5 - 15 mm /
1
/10” - 1/2” stainless steel 1.4462 Duplex
DN 25 - 150 mm / 1” - 6” stainless steel 1.4301/304-AISI
Terminal box
Standard die cast aluminium, paint finish
Special version stainless steel 1.4301/304-AISI, others on request
Installation instructions VARIFLUX 6000 11
Page 12
12 Dimensions and weights
12 Installation instructions VARIFLUX 6000
Page 13
Dimension LM see Table on Page 12
Installation instructions VARIFLUX 6000 13
Page 14
Dimension LM see Table on Page 12
14 Installation instructions VARIFLUX 6000
Page 15
If you need to return flowmeters for testing or repair to KROHNE
Your electromagnetic flowmeter
• has been carefully manufactured and
tested by a company with ISO 9001
certification
• and volumetrically calibrated in one of the
world’s most accurate test rigs.
If installed and operated in accordance with
these operating instructions, your flowmeter
will rarely present any problems.
Should you nevertheless need to return a
flowmeter for checkout or repair, please pay
strict attention to the following points:
Due to statutory regulations concerning
protection of the environment and the health
and safety of our personnel, Krohne may only
handle, test and repair returned flowmeters
that have been in contact with liquids if it is
possible to do so without risk to personnel
and environment. This means that Krohne
can only service your flowmeter if it is
accompanied by a certificate in line with the
following model confirming that the flowmeter is
safe to handle.
If the flowmeter has been operated with toxic,
caustic, flammable or water-endangering
liquids, you are kindly requested
• to check and ensure, if necessary by rinsing
or neutralizing, that all cavities in the
flowmeter are free from suchdangerous
substances.
(Directions on how you can find out whether
the flow sensor has to be opened and then
flushed out or neutralized are obtainable
from Krohne on request.)
• to enclose a certificate with the flowmeter
confirming that the flowmeter is safe to
handle and stating the liquid used.
KROHNE regret that they cannot service your
flowmeter unless accompanied by such a
certificate.
S P E C I M E N certificate
Company: ……………………………………….. Address: ……………………………………………
Department: …………………………………….. Name: ………………………………………………
Tel. No.: ………………………………………….
The enclosed electromagnetic flowmeter
Type: …………………………………………….. KROHNE Order No. or Series No ………………
has been operated with the following liquid: ……………………………………………………………..
Because this liquid is
water-endangering * / toxic * / caustic * / flammable *
we have
– checked that all cavities in the flowmeter are free from such substances *
– flushed out and neutralized all cavities in the flowmeter *
(* delete if not applicable)
We confirm that there is no risk to man or environment through any residual liquid contained in
this flowmeter.
Date: ………………………….. Signature: ……………………………………………………………..
Company stamp:
Installation instructions VARIFLUX 6000 15
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