KROHNE OPTIFLUX 1000 User manual

Electromagnetic flow sensor in sandwich design
OPTIFLUX 1000
OPTIFLUX 1000OPTIFLUX 1000
OPTIFLUX 1000 Quick Start
Quick StartQuick Start
Quick Start
© KROHNE 01/2013 - 4002298501 - QS OPTIFLUX 1000 R04 en
The documentation is only complete when used in combination with the relevant
documentation for the signal converter.

CONTENTS
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OPTIFLUX 1000
1 Safety instructions 3
2 Installation 4
2.1 Scope of delivery............................................................................................................... 4
2.2 Device description ............................................................................................................ 5
2.3 Nameplate ........................................................................................................................ 6
2.4 Storage ............................................................................................................................. 7
2.5 Transport .......................................................................................................................... 7
2.6 Pre-installation requirements ......................................................................................... 7
2.7 General requirements ...................................................................................................... 8
2.7.1 Vibration .................................................................................................................................. 8
2.7.2 Magnetic field.......................................................................................................................... 8
2.8 Installation conditions ...................................................................................................... 9
2.8.1 Inlet and outlet ........................................................................................................................ 9
2.8.2 Bends in 2 or 3 dimensions..................................................................................................... 9
2.8.3 T-section ................................................................................................................................. 9
2.8.4 Bends .................................................................................................................................... 10
2.8.5 Open discharge ..................................................................................................................... 10
2.8.6 Flange deviation.................................................................................................................... 11
2.8.7 Control valve ......................................................................................................................... 11
2.8.8 Pump ..................................................................................................................................... 11
2.8.9 Air venting and vacuum forces ............................................................................................. 12
2.8.10 Mounting position................................................................................................................ 13
2.9 Mounting ......................................................................................................................... 13
2.9.1 Torques and pressures......................................................................................................... 13
2.10 Temperatures ............................................................................................................... 15
3 Electrical connections 16
3.1 Safety instructions.......................................................................................................... 16
3.2 Grounding ....................................................................................................................... 16
3.3 Virtual reference for IFC 300 (C, W and F version) ........................................................ 17
3.4 Connection diagrams ..................................................................................................... 17
4 Technical data 18
4.1 Dimensions and weights ................................................................................................ 18

SAFETY INSTRUCTIONS 1
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Warnings and symbols used
HANDLING
• This symbol designates all instructions for actions to be carried out by the operator in the
specified sequence.
iRESULT
RESULTRESULT
RESULT
This symbol refers to all important consequences of the previous actions.
Safety instructions for the operator
DANGER!
This information refers to the immediate danger when working with electricity.
DANGER!
These warnings must be observed without fail. Even partial disregard of this warning can lead to
serious health problems and even death. There is also the risk of seriously damaging the device
or parts of the operator's plant.
WARNING!
Disregarding this safety warning, even if only in part, poses the risk of serious health problems.
There is also the risk of damaging the device or parts of the operator's plant.
CAUTION!
Disregarding these instructions can result in damage to the device or to parts of the operator's
plant.
INFORMATION!
These instructions contain important information for the handling of the device.
CAUTION!
Installation, assembly, start-up and maintenance may only be performed by appropriately
trained personnel. The regional occupational health and safety directives must always be
observed.
LEGAL NOTICE!
The responsibility as to the suitability and intended use of this device rests solely with the user.
The supplier assumes no responsibility in the event of improper use by the customer. Improper
installation and operation may lead to loss of warranty. In addition, the "Terms and Conditions of
Sale" apply which form the basis of the purchase contract.
INFORMATION!
• Further information can be found on the supplied CD-ROM in the manual, on the data sheet,
in special manuals, certificates and on the manufacturer's website.
• If you need to return the device to the manufacturer or supplier, please fill out the form
contained on the CD-ROM and send it with the device. Unfortunately, the manufacturer
cannot repair or inspect the device without the completed form.

2INSTALLATION
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2.1 Scope of delivery
INFORMATION!
Do a check of the packing list to make sure that you have all the elements given in the order.
INFORMATION!
Inspect the cartons carefully for damages or signs of rough handling. Report damage to the
carrier and to the local office of the manufacturer.
INFORMATION!
The remote version will arrive in two cartons. One carton contains the converter and one carton
contains the sensor.
Figure 2-1: Scope of delivery
1 Ordered flowmeter
2 Product documentation
3 Factory calibration report
4 CD-ROM with product documentation in available languages
5 Grounding rings (optional)
6 Signal cable (remote versions only)
INFORMATION!
Assembly materials and tools are not part of the delivery. Use the assembly materials and tools
in compliance with the applicable occupational health and safety directives.

INSTALLATION 2
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2.2 Device description
Your measuring device is supplied ready for operation. The factory settings for the operating
data have been made in accordance with your order specifications.
The following versions are available:
•Compact version (the signal converter is mounted directly on the measuring sensor)
•Remote version (a measuring sensor with connection box and a separate signal converter)
1 Remote version (DN15...40)
2 Remote version (DN50...150)
3 Compact version with IFC 300 signal converter
4 Compact version with IFC 100 (0°) signal converter
5 Compact version with IFC 100 (45°) signal converter
6 Compact version with IFC 050 (10°) signal converter

2INSTALLATION
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2.3 Nameplate
INFORMATION!
Check the device nameplate to ensure that the device is delivered according to your order.
Additional information (a.o correct supply voltage), can be found in the documentation of the
signal converter.
1 Name and address of the manufacturer
2 Type designation of the flowmeter and CE sign with number(s) of notified body / bodies
3 Calibration data
4 PED data

INSTALLATION 2
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2.4 Storage
•Store the device in a dry and dust-free location.
•Avoid lasting direct exposure to the sun.
•Store the device in its original packaging.
•Storage temperature: -50 ...+70°C / -58...+158°F
2.5 Transport
Signal converter
•No special requirements.
Compact version
•Do not lift the device by the signal converter housing.
•Do not use lifting chains.
•To transport the device, use lifting straps. Wrap these around both process connections.
2.6 Pre-installation requirements
Make sure that you have all necessary tools available:
•Allen key (4 mm)
•Small screwdriver
•Wrench for cable glands
•Wrench for wall mounting bracket (remote version only)
•Torque wrench for installing flowmeter in pipeline
Figure 2-2: Transport

2INSTALLATION
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2.7 General requirements
2.7.1 Vibration
2.7.2 Magnetic field
INFORMATION!
The following precautions must be taken to ensure reliable installation.
• Make sure that there is adequate space to the sides.
• Protect the signal converter from direct sunlight and install a sun shade if necessary.
• Signal converters installed in control cabinets require adequate cooling, e.g. by fan or heat
exchanger.
• Do not expose the signal converter to intense vibration. The flowmeters are tested for a
vibration level in accordance with IEC 68-2-64.
Figure 2-3: Avoid vibrations
Figure 2-4: Avoid magnetic fields

INSTALLATION 2
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2.8 Installation conditions
2.8.1 Inlet and outlet
Use straight inlet and outlet pipe sections to prevent flow distortion or swirl, caused by bends
and T- sections
2.8.2 Bends in 2 or 3 dimensions
2.8.3 T-section
Figure 2-5: Recommended inlet and outlet section
1 Refer to chapter "Bends in 2 or 3 dimensions"
2 ≥2 DN
Figure 2-6: 2 and 3 dimensional bends, in front of flowmeter
1 Bends in 2 dimensions: ≥5 DN; bends in 3 dimensions: ≥10 DN
Figure 2-7: Distance behind a T-section
1 ≥10 DN

2INSTALLATION
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2.8.4 Bends
2.8.5 Open discharge
Figure 2-8: Installation in bending pipes
Figure 2-9: Installation in bending pipes
CAUTION!
Avoid draining or partial filling of the flow sensor
Figure 2-10: Installation in front of an open discharge

INSTALLATION 2
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2.8.6 Flange deviation
2.8.7 Control valve
2.8.8 Pump
CAUTION!
Max. permissible deviation of pipe flange faces:
L
max
- L
min
≤0.5 mm / 0.02"
Figure 2-11: Flange deviation
1 Lmax
2 Lmin
Figure 2-12: Installation in front of a control valve
Figure 2-13: Installation behind a pump

2INSTALLATION
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2.8.9 Air venting and vacuum forces
Figure 2-14: Air venting
1 ≥5 m
2 Air ventilation point
Figure 2-15: Vacuum
1 ≥5 m

INSTALLATION 2
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2.8.10 Mounting position
2.9 Mounting
2.9.1 Torques and pressures
The maximum pressure and torques values for the flowmeter are theoretical and calculated for
optimum conditions and use with carbon steel flanges.
Tightening of bolts
• Always tighten the bolts uniformely and in diagonally opposite sequence.
• Do not exceed the maximum torque value.
• Step 1: Apply approx. 50% of max. torque given in table.
• Step 2: Apply approx. 80% of max. torque given in table.
• Step 3: Apply 100% of max. torque given in table.
Figure 2-16: Mounting position
Figure 2-17: Tightening of bolts

2INSTALLATION
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EN 1092-1
ASME B 16.5
Nominal size
DN [mm]
Counter flanges Maximum
operating
pressure
[bar]
Bolts Max. torque
[Nm]
2
Flange size
DN [mm]
Flange
class[lb]
10 15
1
PN 16/40 ≤16 4 x M12 16
15 15 PN 16/40 ≤16 4 x M12 16
25 25 PN 16/40 ≤16 4 x M12 16
40 40 PN 16/40 ≤16 4 x M16 25
50 50 PN 16/40 ≤16 4 x M16 45
80 80 PN 16/40 ≤16 4 x M16 25
100 100 PN 16 ≤16 8 x M16 33
100 100 PN 40 ≤16 8 x M20 33
150 150 PN 16 ≤16 8 x M20 82
150 150 PN 40 ≤16 8 x M24 82
1 For DN10 and 15 sizes use DN15 counter (pipe) flanges.
2 The specified torque values are dependent on variables (temperature, bolt material, gasket material,lu-
bricants, etc.) which are not within the control of the manufacturer. Therefore the values should be re-
garded as indicative only.
Nominal size
DN [inch]
Counter flanges Max.operating
pressure
[psig]
Bolts Max. torque
[lbs.ft]
2
Flange size
DN (inch)
Flange class
3/8" 1/2"
1
150/300 lb 230 4x 1/2" 11,6
1/2" 1/2" 150/300 lb 230 4x 1/2" 11,6
1" 1" 150/300 lb 230 4x 1/2" 10,8
1 1/2" 1 1/2" 150/300 lb 230 4x 1/2" 18,1
2" 2" 150/300 lb 230 4x 5/8" 32,5
3" 3" 150 lb 230 4x 5/8" 40,5
3" 3" 300 lb 230 8 x 5/8" 20,5
4" 4" 150/300 lb 230 8 x 5/8" 26
6" 6" 150 lb 230 8 x 3/4" 72,3
6" 6" 300 lb 230 12 x 3/4" 47,7
1 For DN3/8" and 1/2" use DN1/2" counter (pipe) flanges.
2 The specified torque values are dependent on variables (temperature, bolt material, gasket material,lu-
bricants, etc.) which are not within the control of the manufacturer. Therefore the values should be re-
garded as indicative only.
CAUTION!
• Pressures are applicable at 20 ° C / 68 ° F.
• For higher temperatures, the pressure ratings are as per ASME B16.5.

INSTALLATION 2
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2.10 Temperatures
CAUTION!
Protect the device from direct sunlight.
Temperature range Process [°C] Ambient [°C] Process [°F] Ambient [°F]
min. max. min. max. min. max. min. max.
Separate flow sensor -25 120 -25 65 -13 248 -13 149
Compact + IFC 300 -25 120 -25 65 -13 248 -13 149
Compact + IFC 100 -25 120 -25 65 -13 248 -13 149
Compact + IFC 050 -25 120 -25 65 -13 248 -13 149

3ELECTRICAL CONNECTIONS
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3.1 Safety instructions
3.2 Grounding
Grounding ring number 1 (optional for DN25...150):
•Thickness: 3 mm / 0.1" (tantalum: 0.5 mm / 0.02")
Note:
Note:Note:
Note: For diameter DN10 and DN15, grounding rings are integrated as standard in the flow
sensor construction.
DANGER!
All work on the electrical connections may only be carried out with the power disconnected. Take
note of the voltage data on the nameplate!
DANGER!
Observe the national regulations for electrical installations!
WARNING!
Observe without fail the local occupational health and safety regulations. Any work done on the
electrical components of the measuring device may only be carried out by properly trained
specialists.
INFORMATION!
Look at the device nameplate to ensure that the device is delivered according to your order.
Check for the correct supply voltage printed on the nameplate.
DANGER!
The device must be grounded in accordance with regulations in order to protect personnel
against electric shocks.
Figure 3-1: Grounding
1 Metal pipelines, not internally coated. Grounding without grounding rings!
2 Metal pipelines with internal coating and non-conductive pipelines. Grounding with grounding rings!
Figure 3-2: Grounding ring number 1

ELECTRICAL CONNECTIONS 3
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3.3 Virtual reference for IFC 300 (C, W and F version)
The virtual reference option on the IFC 300 flow converter provides complete isolation of the
measurement circuit.
Benefits of virtual reference:
•Grounding rings or grounding electrodes can be omitted.
•Safety increases by reducing the number of potential leakage points.
•The installation of the flowmeters is much easier.
Minimum requirements:
•Size: ≥DN10
•Electrical conductivity: ≥200 µS/cm
•Electrode cable: max. 50 m / 164 ft, type DS
3.4 Connection diagrams
Figure 3-3: Virtual reference
INFORMATION!
For the connection diagrams please refer to the documentation of the applicable signal
converter.

4TECHNICAL DATA
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4.1 Dimensions and weights
Remote version
Remote versionRemote version
Remote version a = 88 mm / 3.5"
b = 139 mm / 5.5" 1
c = 106 mm / 4.2"
Total height = H + a
Compact version with
Compact version withCompact version with
Compact version with
IFC 300
IFC 300IFC 300
IFC 300 a = 155 mm / 6.1"
b = 230 mm / 9.1" 1
c = 260 mm / 10.2"
Total height = H + a
Compact version with
Compact version withCompact version with
Compact version with
IFC 100 (0
IFC 100 (0IFC 100 (0
IFC 100 (0°)
))
)a = 82 mm / 3.2"
b = 161 mm / 6.3"
c = 257 mm / 10.1" 1
Total height = H + a
Compact version with
Compact version withCompact version with
Compact version with
IFC 100 (45
IFC 100 (45IFC 100 (45
IFC 100 (45°)
))
)a = 186 mm / 7.3"
b = 161 mm / 6.3"
c = 184 mm / 2.7" 1
Total height = H + a
Compact version with
Compact version withCompact version with
Compact version with
IFC 050 (10
IFC 050 (10IFC 050 (10
IFC 050 (10°)
))
)a = 101 mm / 3.98"
b = 157 mm / 6.18"
c = 260 mm / 10.24" 1
Total height = H + a
1The value may vary depending on the used cable glands.

TECHNICAL DATA 4
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EN 1092-1
ASME B16.5
INFORMATION!
• All data given in the following tables are based on standard versions of the flow sensor only.
• Especially for smaller nominal sizes of the flow sensor, the signal converter can be bigger
than the flow sensor.
• Note that for other pressure ratings than mentioned, the dimensions may be different.
• For full information on signal converter dimensions see relevant documentation.
Nominal size Dimensions [mm] Approx. weight
[kg]
DN L H W
10 68 137 47 1.7
15 68 137 47 1.7
25 54 147 66 1.7
40 78 162 82 2.6
50 100 151 101 4.2
80 150 180 130 5.7
100 200 207 156 10.5
150 200 271 219 15.0
Nominal size Dimensions [inch] Approx. weight
[lb]
ASME L H W
3/8" 2.68 5.39 1.85 3.7
½"2.68 5.39 1.85 3.7
1" 2.13 5.79 2.6 3.7
1½"3.07 6.38 3.23 5.7
2" 3.94 5.94 3.98 9.3
3" 5.91 7.08 5.12 12.6
4" 7.87 8.15 6.14 23.1
6" 7.87 10.67 8.62 33.1

KROHNE product overview
•Electromagnetic flowmeters
•Variable area flowmeters
•Ultrasonic flowmeters
•Mass flowmeters
•Vortex flowmeters
•Flow controllers
•Level meters
•Temperature meters
•Pressure meters
•Analysis products
•Products and systems for the oil & gas industry
•Measuring systems for the marine industry
Head Office KROHNE Messtechnik GmbH
Ludwig-Krohne-Str. 5
47058 Duisburg (Germany)
Tel.:[phone]
Fax:[phone]
[email protected]
© KROHNE 01/2013 - 4002298501 - QS OPTIFLUX 1000 R04 en - Subject to change without notice.
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www.krohne.com