installation and operating instructions...

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Installation andoperating instructions

ENVIROMAGIFS 4000 KC F010 K020 K080 KElectromagnetic flowmetersfor water and sewage

Variable area flowmeters

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Flow controllers

Electromagnetic flowmeters

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© KROHNE 04/2004 7.x0xxx.xx.00

● Primary head

● Compact flowmeter

Subject to change without notice.

2 ENVIROMAG IFS 4000 KC F

General advice on safety

• Do not install, operate or maintain this flow meter without reading, understanding and following the factory-supplied instructions, otherwise injury or damage may result.

• Read these instructions carefully before starting installation and save them for future reference. • Observe all warnings and instructions marked on the product. • Use only mains supply with protective earthing connected. • Do not use the product with removed covers under wet conditions. • Consider handling and lifting instructions to avoid damage. • Install the product securely and stable. • Install and connect cabling proper to exclude damage or harmful situations. • If the product does not operate normally, refer to the service instructions or refer to qualified KROHNE

service engineers. • There are no operator-serviceable parts inside the product.

The following symbols may appear in this manual or on the product

ATTENTION: Refer to operating and installation instructions!

DANGER: Risk of electric shock!

PROTECTIVE EARTH (PE) conductor terminal!

These terms may appear in this manual or on the instrument:

WARNING statement: Identify conditions or practice that could result in injury or loss of life.

CAUTION statement: Identify conditions or practice that could result in damage to the instrument or other property.

Disclaimer • This document contains important information on the instrument. KROHNE attempts to be as accurate and up-to-date as possible but assumes no responsibility for errors or omissions. Nor does KROHNE make any commitment to update the information contained herein. This manual and all other documents are subject to change without prior notice.

• KROHNE will not be liable for any damage of any kind by using its instrument, including, but not limited to direct, indirect, incidental, punitive and consequential damages.

• This disclaimer does not apply in case KROHNE has acted on purpose or with gross negligence. In the event any applicable law does not allow such limitations on implied warranties or the exclusion of limitation of certain damages, you may, if such law applies to you, not be subject to some or all of the above disclaimer, exclusions or limitations.

• Any instrument purchased from KROHNE is warranted in accordance with the relevant product documentation and our Terms and Conditions of Sale.

• KROHNE reserves the right to alter the content of its documents, including this disclaimer in any way, at any time, for any reason, without prior notification, and will not be liable in any way for possible consequences of such changes.

ENVIROMAG IFS 4000 KC F 3

Product liability and warranty

IFS 4000 KC electromagnetic flowmeters are designed solely for measuring the volumetric flowrate of electrically conductive, liquid process products. Flowmeters with IFS 4000 KC flow sensors are not certified for use in hazardous locations. Other flowmeters series are available for such applications. 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 IFS 4000 KC flowmeters need to be returned to Krohne, please note the information given on the last-but-one page of this manual. KROHNE regrets that they cannot repair or check your flowmeter(s) unless accompanied by the completed form sheet

• Responsibility for suitability and intended use of this ultrasonic flow meter rests solely with the user. Improper installation and operation of the flow meter (system) may lead to loss of warranty.

• In addition, the Terms and Conditions of Sale are applicable and are the basis for the purchase contract. • If flow meters need to be returned to KROHNE, please note the information given on the last pages of the

installation and operating instructions. KROHNE regrets that they cannot repair or check flow meter(s) unless accompanied by the completed form (see last pages of the installation and operating instructions).

Contents

1 1 Important information for installation: .................................................................................................................................5

2 Suggestions for installation .....................................................................................................................................................5

3 Instrument nameplate ...............................................................................................................................................................6

4 Flowmeter versions...................................................................................................................................................................6

5 Installation in the pipeline ........................................................................................................................................................6

6 Torques ......................................................................................................................................................................................6

7 Grounding ..................................................................................................................................................................................6

8 Replacement of the separate flow sensor ..............................................................................................................................7

9 Technical data ...........................................................................................................................................................................8

10 Dimensions and weights ..........................................................................................................................................................9


System description

IFS 4000 KC electromagnetic flowmeters are precision measuring instruments designed for the linear flow measurement of process liquids. The process liquids must be electrically conductive: ≥ 20 µS/cm for demineralized cold water The full-scale range Q100% can be set as a function of the meter size: IFS 4000 KC 010 K / 020 K / 080 K 1” - 040” Q100% = 0.1 - 033 900 m3/hr = 0.02 - 1156 640 US GPM IFS 4000 KC 1 - 120” Q100% = 0.1 - 305 000 m3/hr = 0.02 - 1 400 000 US GPM This is equivalent to a flow velocity of 0.3 - 12 m/s, or 1 - 40 ft/s

Standards and approvals Please refer to the installation and operating instructions for the signal converter.

Items supplied

IFS 4000 KC F flow sensors • flow sensor in the size as ordered • Connecting wires for grounding, refer to Section 7 ”Grounding” • Certificate of calibration data • Grounding rings (optional), if ordered • Installation instructions

IFS 4000 KC 010 K, 020 K and 080 K compact flowmeters

• Compact flowmeter in the size as ordered • Connecting wires for grounding, see • Section 7 ”Grounding” • Certificate of calibration data • Grounding rings (optional), if ordered • Installation instructions • Installation and operating instructions for the signal converter • Items included with supply

Fitting accessories (stud bolts, nuts, gaskets, etc.) are not supplied with the flowmeter. These are to be provided by the customer! IFS 4000 KC 010 K, 020 K and 080 K compact flowmeters

• Compact flowmeter in the size as ordered • Connecting wires for grounding, see • Section 7 ”Grounding” • Certificate of calibration data • Grounding rings (optional), if ordered • Installation instructions • Installation and operating instructions for the signal converter • Items included with supply

Handling

Do not lift the signal converter housing or the terminal box. Check the weight of the flow meter as indicated on the type plate before handling the unit. When handling the flow meter avoid hard blows, jolts or impacts

Do not set flowmeter down on signal converter housing or terminal box.

PLEASE NOTE the temperature limits for storage and transport.


1 1 Important information for installation: PLEASE NOTE !

• 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 completetly 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: below 2.2g for compact flowmeters in the frequency range of 20-50 Hz with the IFC 010 K / IFC 020 K and 20-150 Hz with the IFC 090 K.

• Do not expose to direct sunlight, fit a sunshade if necessary, not included with flowmeter, to be provided by customer.

• Large meter sizes (≥ DN 200 / ≥ 8”): use adapter pipes to allow axial shifting of the counterflanges and to facilitate installation.

• Use only solventless detergents to clean the signal converter housing (polycarbonate). • 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. • Plastic pipes and internally coated metal pipelines: grounding rings required, see Section 7 ”Grounding”. • 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:


3 Instrument nameplate

IFS 4000 KC F separate flow sensor

4 Flowmeter versions

IFS 4000 KC F, Separate flow sensor (F), electrically connected to the signal converter by signal and field current cables. IFS 4000 KC 010 K, Compact flowmeter (K), IFC 010 K or IFC 020 K signal converter mounted IFS 4000 KC 020 K, direct on the flow sensor. IFS 4000 KC 080 K; Compact flowmeter (K), IFC 090 K signal converter mounted direct on the flow sensor.

5 Installation in the pipeline

• Installation material not included, to be provided by customer (stud bolts, nuts, gaskets, etc.) • Pipe flanges and operating pressure: refer to tables on ”limits” in Section 11. • Distance between pipe flanges

see fitting dimension ”a”, in Section 10 ”Dimensions and weights”. • Position of flanges Install flowmeter in line with the pipe axis. Pipe flange faces must be parallel to each

other, max. permissible deviation: • Lmax – Lmin ≤ 0.5 mm ≤ 0.02” • Gaskets

Use gaskets suitable for the application and appropriate to the liner, not included with flowmeter, to be provided by customer.

• Grounding rings / protective rings (option) On plastic pipes and internally coated metal pipelines, grounding rings must form the conductive connection with the fluid. Refer to Section 7 ”Grounding for electrical connection.

6 Torques

• Tighten stud bolts uniformly in diagonally opposite sequence, see table for number and type. • 10 Nm ~ 1.0 kpm ~ 7.23 ft × lbf • Note: Process pressure must not exceed ANSI

7 Grounding

• 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.

IFS 4000 KCF separate flow sensor with terminal box

• An FE functional ground must always be connected. • Signal converter with field power supply > 125 mA / 60 V a PE protective conductor must be connected to

the flow sensor, because of the higher field current from the signal converter. See grounding diagrams below.

IFS 4000 KC010 K, 020 K and 080 K 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.

Power supply 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 Replacement of the separate flow sensor 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 Q100% and the 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.


9 Technical data

Meter sizesCompact syste 1" – 040”IFS 4000 KCF (separate) 1" – 60”Pipe flangesto DIN 2501 (= BS 4504)to ANSI B16.5 1" – 24” / Class 150 lb / RFto AWWA 28” – 60” / Class B or D / FFElectrical conductivity ≥ 20 µS/cmTemperatures Ambient temperature Process temperatureCompact systems

– 13 to +140°F – 13 to ≤ +140°F– 13 to +140°F – 13 to +140°F

IFS 4000 KCF (separate) – 13 to +140°F – 13 to +176°FMax. allowable operating data

for the liner, refer to Page 3 “Limits”Insulation class of field coils EElectrode design1" – 60’’ flat elliptical electrodes, solidly fitted,

surface-polishedProtection category (EN 60 529 / IEC 529)Standard IP 67, equivalent to NEMA 6Option IP 68, equivalent to NEMA 6Grounding rings available as an optionMaterialsMeasuring tube stainless steel 1.4301 (or higher materials number),

equivalent to SS 304

Liner1 - 40” polyurethane1’’ – 60’’ hard rubber

ElectrodesStandard Hastelloy C4Option stainless steel 1.4571 or SS 316 Ti, titanium

Connecting flanges*ANSI steel ASTM A 105 N

Terminal box*IFS 4000 KCF (separate) die-cast aluminiumGrounding rings (option) stainless steel 1.4571or SS 316 Ti

* with polyurethane coating

Process temperature, operating pressure and vacuum load


10 Dimensions and weights Terminal box IFC 010 K and IFC 020 K

signal converters IFC 090 K s9ignal converter

Weight approx. 0.5 kg (1.1 lb) Weight approx. 1.6 kg (3.6 lb) Weight approx. 2.3 kg (5.1 lb)

Dimension “a” without flange gaskets: Not included with flowmeter to be provided by customer

Nominal Diameter WeightANSI approx.Inch DIN ISO ANSI DIN ISO ANSI DIN ISO ANSI DIN ISO ANSI lb

1 5.91 5.91 9.21 9.21 5.12 5.12 4.53 4.25 6.901 1/2 5.91 5.91 9.21 9.21 5.12 5.12 5.91 5.00 13.20

2 7.87 7.87 7.52 7.28 6.50 6.00 6.50 6.00 17.603 7.87 7.87 8.23 8.03 7.87 7.50 7.87 7.50 37.504 9.84 9.84 10.04 10.24 8.66 8.98 8.66 8.98 41.906 11.81 11.81 11.81 11.69 11.22 10.98 11.22 10.98 57.308 13.78 13.78 14.06 14.17 13.39 13.50 13.90 13.50 110.20

10 15.75 15.75 16.97 17.20 15.55 16.00 15.55 16.00 161.0012 19.69 19.69 19.02 19.76 17.52 19.02 17.52 19.02 218.3014 19.69 19.69 21.30 21.85 19.88 21.00 19.88 21.00 251.3016 23.62 23.62 24.92 24.92 22.24 23.50 22.24 23.50 337.3018 23.62 23.62 26.22 26.54 24.21 25.00 24.21 25.00 374.8020 23.62 23.62 28.11 28.62 26.38 26.38 26.38 27.50 418.9024 23.62 23.62 33.07 33.66 30.71 32.00 30.71 32.00 551.10

Dimensions in inches (ANSI)A B C D

150 lb / RF see table≥ 300 lb / RF dimensions supplied on request

AWWA ≥ 28" Class B, D / FF dimensions supplied on request

Flange connections to… Dimensions in inchANSI B 16.5 1" - 24"


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

such dangerous substances. (Directions on how you can find out whether the primary head 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.: ………………………………………………………………………….. Fax No.: ………………………………………………………………………….. The enclosed instrument 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 instrument 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 the instrument. Date: ………………………………………………………… Signature: …………………………………………………………………………………………….. Company stamp:


Notes

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Subject to change without notice

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