KROHNE WATERFLUX 3000 User manual

Electromagnetic flow / water meter
WATERFLUX 3000
WATERFLUX 3000WATERFLUX 3000
WATERFLUX 3000 Handbook
HandbookHandbook
Handbook
© KROHNE 11/2009 - 7311232200 - HB WATERFLUX 3000 R02 en
The documentation is only complete when used in combination with the relevant
documentation for the converter.

All rights reserved. It is prohibited to reproduce this documentation, or any part thereof, without
the prior written authorisation of KROHNE Messtechnik GmbH.
Subject to change without notice.
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Copyright 2009 by
KROHNE Messtechnik GmbH - Ludwig-Krohne-Str. 5 - 47058 Duisburg (Germany)
:IMPRINT ::::::::::::::::::::::::::::::::::

CONTENTS
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WATERFLUX 3000
1 Safety instructions 5
1.1 Intended use ..................................................................................................................... 5
1.2 Safety instructions from the manufacturer ..................................................................... 5
1.2.1 Copyright and data protection ................................................................................................ 5
1.2.2 Disclaimer ............................................................................................................................... 5
1.2.3 Product liability and warranty ................................................................................................ 6
1.2.4 Information concerning the documentation........................................................................... 6
1.2.5 Warnings and symbols used................................................................................................... 7
1.3 Safety instructions for the operator................................................................................. 7
2 Device description 8
2.1 Nameplates ...................................................................................................................... 8
2.2 Instrument description.....................................................................................................8
2.3 Scope of delivery............................................................................................................... 8
2.4 Nameplate ........................................................................................................................ 9
3 Installation 10
3.1 Notes on installation ......................................................................................................10
3.2 Storage ........................................................................................................................... 10
3.3 Transport ........................................................................................................................ 10
3.4 Pre-installation requirements ....................................................................................... 10
3.5 Installation requirements .............................................................................................. 11
3.5.1 Inlet and outlet ...................................................................................................................... 11
3.5.2 Mounting position.................................................................................................................. 11
3.5.3 Flange deviation.................................................................................................................... 11
3.5.4 T-section ............................................................................................................................... 12
3.5.5 Vibration ................................................................................................................................ 12
3.5.6 Magnetic field........................................................................................................................ 13
3.5.7 Bends .................................................................................................................................... 13
3.5.8 Open discharge ..................................................................................................................... 14
3.5.9 Control valve ......................................................................................................................... 14
3.5.10 Air venting ........................................................................................................................... 14
3.5.11 Pump ................................................................................................................................... 15
3.6 Installation of sensor...................................................................................................... 16
4 Electrical connections 18
4.1 Safety instructions.......................................................................................................... 18
4.2 Grounding ....................................................................................................................... 18
4.3 Signal cable .................................................................................................................... 19
4.4 Connection of signal cable ............................................................................................. 19
5 Start-up 20
5.1 Start up ........................................................................................................................... 20

CONTENTS
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WATERFLUX 3000
6 Service 21
6.1 Spare parts availability...................................................................................................21
6.2 Availability of services .................................................................................................... 21
6.3 Returning the device to the manufacturer..................................................................... 22
6.3.1 General information.............................................................................................................. 22
6.3.2 Form (for copying) to accompany a returned device............................................................ 23
6.4 Disposal .......................................................................................................................... 23
7 Technical data 24
7.1 Technical data................................................................................................................. 24
7.2 Measuring accuracy ....................................................................................................... 28
7.3 Vacuum load ................................................................................................................... 29
7.4 Dimensions and weights ................................................................................................ 29
8 Notes 31

SAFETY INSTRUCTIONS 1
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1.1 Intended use
This WATERFLUX 3000 water meter has been designed for measuring potable water and water
with suspended particles. It can be combined with an IFC 070 signal converter or with a IFC 100 /
300 converter.
1.2 Safety instructions from the manufacturer
1.2.1 Copyright and data protection
The contents of this document have been created with great care. Nevertheless, we provide no
guarantee that the contents are correct, complete or up-to-date.
The contents and works in this document are subject to German copyright. Contributions from
third parties are identified as such. Reproduction, processing, dissemination and any type of use
beyond what is permitted under copyright requires written authorisation from the respective
author and/or the manufacturer.
The manufacturer tries always to observe the copyrights of others, and to draw on works created
in-house or works in the public domain.
The collection of personal data (such as names, street addresses or e-mail addresses) in the
manufacturer's documents is always on a voluntary basis whenever possible. Whenever
feasible, it is always possible to make use of the offerings and services without providing any
personal data.
We draw your attention to the fact that data transmission over the Internet (e.g. when
communicating by e-mail) may involve gaps in security. It is not possible to protect such data
completely against access by third parties.
We hereby expressly prohibit the use of the contact data published as part of our duty to publish
an imprint for the purpose of sending us any advertising or informational materials that we have
not expressly requested.
1.2.2 Disclaimer
The manufacturer will not be liable for any damage of any kind by using its product, including,
but not limited to direct, indirect, incidental, punitive and consequential damages.
This disclaimer does not apply in case the manufacturer 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 product purchased from the manufacturer is warranted in accordance with the relevant
product documentation and our Terms and Conditions of Sale.
The manufacturer 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.

1SAFETY INSTRUCTIONS
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1.2.3 Product liability and warranty
The operator shall bear responsibility for the suitability of the device for the specific purpose.
The manufacturer accepts no liability for the consequences of misuse by the operator. Improper
installation and operation of the devices (systems) will cause the warranty to be void. The
respective "Standard Terms and Conditions" which form the basis for the sales contract shall
also apply.
1.2.4 Information concerning the documentation
To prevent any injury to the user or damage to the device it is essential that you read the
information in this document and observe applicable national standards, safety requirements
and accident prevention regulations.
If this document is not in your native language and if you have any problems understanding the
text, we advise you to contact your local office for assistance. The manufacturer can not accept
responsibility for any damage or injury caused by misunderstanding of the information in this
document.
This document is provided to help you establish operating conditions, which will permit safe and
efficient use of this device. Special considerations and precautions are also described in the
document, which appear in the form of underneath icons.

SAFETY INSTRUCTIONS 1
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1.2.5 Warnings and symbols used
Safety warnings are indicated by the following symbols.
• HANDLING
HANDLINGHANDLING
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.
1.3 Safety instructions for the operator
DANGER!
This information refers to the immediate danger when working with electricity.
DANGER!
This warning refers to the immediate danger of burns caused by heat or hot surfaces.
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.
LEGAL NOTICE!
This note contains information on statutory directives and standards.
WARNING!
In general, devices from the manufacturer may only be installed, commissioned, operated and
maintained by properly trained and authorized personnel.
This document is provided to help you establish operating conditions, which will permit safe and
efficient use of this device.

2DEVICE DESCRIPTION
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2.1 Nameplates
2.2 Instrument description
Two versions are available. You received a compact version or a remote version.
2.3 Scope of delivery
INFORMATION!
Look at the device nameplate to ensure that the device is delivered according to your order.
Check the correct supply voltage printed on the nameplate.
Figure 2-1: Versions
1 compact version
2 remote version
Figure 2-2: Scope of delivery
1 Ordered flowmeter
2 Quick Start
3 Factory calibration report
4 CD-ROM with product documentation
5 Cable (remote versions only)

DEVICE DESCRIPTION 2
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2.4 Nameplate
INFORMATION!
Look at the device nameplate to ensure that the device is delivered according to your order.
Check the correct supply voltage printed on the nameplate.
Figure 2-3: Example for nameplate
1 Manufacturer
2 Voltage information
3 Electronic Revision number
4 Material of wetted parts
5 Meter constant
6 Serial number
7 Device type

3INSTALLATION
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3.1 Notes on installation
3.2 Storage
•Store the device in a dry, dust-free location.
•Avoid continuous direct sunlight.
•Store the device in its original packaging.
•Storage temperature: -50 ...+70°C / -58...+158°F
3.3 Transport
3.4 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
INFORMATION!
Inspect the cartons carefully for damage or signs of rough handling. Report damage to the
carrier and to the local office of the manufacturer.
INFORMATION!
Check the packing list to check if you received completely all that you ordered.
INFORMATION!
Look at the device nameplate to ensure that the device is delivered according to your order.
Check the correct supply voltage printed on the nameplate.
Figure 3-1: Transport

INSTALLATION 3
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3.5 Installation requirements
3.5.1 Inlet and outlet
3.5.2 Mounting position
3.5.3 Flange deviation
Figure 3-2: Recommended inlet and outlet
1 ≥3 DN for DN25...300
≥5 DN for DN350...600
2 ≥1 DN for DN25...300
≥2 DN for DN350...600
Figure 3-3: Mounting position
CAUTION!
Max. permissible deviation of pipe flange faces:
L
max
- L
min
≤0.5 mm / 0.02"

3INSTALLATION
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3.5.4 T-section
3.5.5 Vibration
Figure 3-4: Flange deviation
1 Lmax
2 Lmin
Figure 3-5: Distance after T-sections
1 DN25...300: ≥3 DN; DN350...600: ≥10 DN
Figure 3-6: Avoid vibrations

INSTALLATION 3
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3.5.6 Magnetic field
3.5.7 Bends
Figure 3-7: Avoid magnetic fields
Figure 3-8: Installation in bending pipes
Figure 3-9: Installation in bending pipes

3INSTALLATION
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3.5.8 Open discharge
3.5.9 Control valve
3.5.10 Air venting
Figure 3-10: Installation before an open discharge
Figure 3-11: Installation before control valve
Figure 3-12: Air venting
1 ≥5 m
2 Air ventilation point

INSTALLATION 3
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3.5.11 Pump
Figure 3-13: Installation after pump

3INSTALLATION
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3.6 Installation of sensor
Here you find the maximum pressure and torques for the flowmeter. All values are theoretical
and calculated for optimum conditions and use with carbon steel flanges.
Nominal size
D N [ m m ]
Pressure
r a t i n g
Bolts Max. torque [Nm]
Rilsan Hardrubber
25 PN 16 4 x M 12 6 -
40 PN 16 4 × M 16 36 -
50 PN 16 4 × M 16 50 -
65 PN 16 4 × M 16 50 -
80 PN 16 8 × M 16 35 -
100 PN 16 8 × M 16 35 -
125 PN 16 8 × M 16 40 -
150 PN 16 8 × M 20 45 -
200 PN 10 12 × M 20 45 -
250 PN 10 12 x M 20 65 -
300 PN 10 12 x M 20 76 -
350 PN 10 16 x M 20 -75
400 PN 10 16 x M 24 -104
450 PN 10 20 x M 24 -93
500 PN 10 20 x M 24 -107
600 PN 10 20 x M 27 -138

INSTALLATION 3
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Procedure to setup max. torque:
•Step 1: approx. 50% of max. torque
•Step 2: approx. 80% of max. torque
•Step 3: 100% of max. torque given in tables before
Nominal size
[inches]
Flange class
[lbs]
Bolts Max. torque [Nm]
Rilsan Hardrubber
1150 4 x 1/2" 6 -
1½150 4 x 1/2" 15 -
2150 4 × 5/8" 25 -
3150 4 × 5/8" 45 -
4150 8 × 5/8" 35 -
5150 8 × 3/4" 45 -
6150 8 × 3/4" 55 -
8150 8 × 3/4" 70 -
10 150 12 x 7/8" 116 -
12 150 12 x 7/8" 144 -
14 150 12 x 1" -93
16 150 16 x 1" -91
18 150 16 x 1 1/8" -143
20 150 20 x 1 1/8" -127
24 150 20 x 1 1/4" -180
Figure 3-14: Maximum torque

4ELECTRICAL CONNECTIONS
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4.1 Safety instructions
4.2 Grounding
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 the correct supply voltage printed on the nameplate.
Figure 4-1: Grounding
INFORMATION!
• DN25..300: the flow sensor is equipped with a reference electrode. Grounding rings are not
necessary!
• DN350...600: Apply grounding rings if required.

ELECTRICAL CONNECTIONS 4
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4.3 Signal cable
4.4 Connection of signal cable
• Prepare appropriate cable lengths (1...3)
• Connect the shield to the U-clamp, the brown cable to terminal 7 and the white to terminal 8.
• Connect the shield to terminal 1, the purple cable (white in case of type A or B cable) to
terminal 2 and the blue (red in case of type A or B cable) to terminal 3.
CAUTION!
To ensure smooth functioning, always use the signal cables included in the delivery.
INFORMATION!
You only receive a signal cable if you ordered a remote version.
INFORMATION!
The signal cable is only used with remote versions. The standard KROHNE WSC-cable includes
both electrode and field current leads, the optional type A / B cable is only used for the
electrodes. In that case, the field current cable is no part of the supply.
Figure 4-2: Cable connection at sensor side, standard cable
1 cable length: 13 cm / 5"
2 cable length: 5 cm / 2"
3 brown + white cable, used for field current
4 purple and blue cable, used for electrode signals
5 cable length: 8 cm / 3"
6 Shield (terminal 1 of connector X2 + U-clamp

5START-UP
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5.1 Start up
INFORMATION!
Please follow the instructions in the documentation of the converter.