KROHNE WATERFLUX 3070 User manual

Battery powered electromagnetic water meter
Electronic Revision ER 4.3.0_
(SW.REV 4.2.2_)
WATERFLUX 3070
WATERFLUX 3070WATERFLUX 3070
WATERFLUX 3070 Quick Start
Quick StartQuick Start
Quick Start
© KROHNE 03/2012 - 7312342300 - QS WATERFLUX 3070 R03 en

CONTENTS
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WATERFLUX 3070
1 Safety instructions 4
1.1 Instruction for transportation and handling of batteries................................................. 5
2 Installation 6
2.1 Scope of delivery............................................................................................................... 6
2.2 Device description ............................................................................................................ 7
2.3 Nameplate ........................................................................................................................ 8
2.4 Storage ............................................................................................................................. 8
2.5 Transport .......................................................................................................................... 8
2.6 Pre-installation requirements ......................................................................................... 9
2.7 Installation conditions ....................................................................................................10
2.7.1 General requirements .......................................................................................................... 10
2.7.2 Inlet and outlet ...................................................................................................................... 10
2.7.3 Vibration ................................................................................................................................ 10
2.7.4 Mounting position and flange deviation................................................................................ 11
2.7.5 T-section ............................................................................................................................... 11
2.7.6 Magnetic field........................................................................................................................ 12
2.7.7 Open discharge ..................................................................................................................... 12
2.7.8 Bends .................................................................................................................................... 12
2.7.9 Control valve ......................................................................................................................... 13
2.7.10 Air venting ........................................................................................................................... 13
2.7.11 Pump ................................................................................................................................... 14
2.7.12 IP68...................................................................................................................................... 15
2.8 Mounting ......................................................................................................................... 16
2.8.1 Torques and pressures......................................................................................................... 16
2.9 Mounting of the field housing, remote version.............................................................. 18
2.9.1 Pipe mounting ....................................................................................................................... 18
2.9.2 Wall mounting....................................................................................................................... 18
2.10 Mounting of the IP68 version........................................................................................ 18
3 Electrical connections 19
3.1 Safety instructions.......................................................................................................... 19
3.2 Grounding ....................................................................................................................... 19
3.3 Connection of the signal cable ....................................................................................... 20
3.3.1 IP 67 housing (field version).................................................................................................. 20
3.4 Connection of the output cable ...................................................................................... 22
3.4.1 IP67 housing (compact and field version)............................................................................. 22
3.4.2 IP68 housing (compact version)............................................................................................ 23
4 Start-up 24
4.1 Connecting the internal battery ..................................................................................... 24
4.2 Connecting the external battery..................................................................................... 25
4.2.1 IP67 housing (compact and field version)............................................................................. 25
4.2.2 IP68 housing (compact version)............................................................................................ 25

CONTENTS
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WATERFLUX 3070
5 Technical data 26
5.1 Dimensions and weights ................................................................................................ 26
6 Notes 28

1SAFETY INSTRUCTIONS
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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.

SAFETY INSTRUCTIONS 1
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1.1 Instruction for transportation and handling of batteries
Please observe the following instructions:
•Transport only in special packaging with special labels and transportation documents.
•Do not short-circuit, recharge, overcharge or connect with false polarity.
•Do not expose to temperature beyond the specified temperature range or incinerate the
battery.
•Do not crush, puncture or open cells or disassemble battery packs.
•Do not weld or solder to the body of the battery.
•Do not expose contents of battery to water.
•Remove the battery from device before returning to the manufacturer for service or warranty
reasons.
•Dispose battery packs in accordance with local regulations; where possible, recycle used
batteries.
WARNING!
The used lithium batteries are primary power sources with high energy content. If mistreated,
they may present a potential risk.
INFORMATION!
The manufacturer assumes no liability for customer failure.

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 watermeter
2 Product documentation
3 Factory calibration report
4 CD-ROM with product documentation in available languages
5 Signal cable (remote versions only)
123
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) in
aluminium (IP67) or polycarbonate (IP68) housing
•Remote version (measuring sensor with connection box and a signal converter in a remote
(field) housing)
Figure 2-2: Device versions
1 Compact version in aluminium (IP67) housing
2 Compact version in polycarbonate (IP68) housing
3 Remote version

2INSTALLATION
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2.3 Nameplate
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 flange devices, use lifting straps. Wrap these around both process connections.
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.
Figure 2-3: Example for nameplate
1 Name and address of the manufacturer
2 CE sign with number(s) of notified body / bodies
3 Battery voltage and Electronic Revision number
4 Optional (MI-001): Additional information including approval number, Q3, ratio
5 Meter constant, diameter, wetted materials, protection class
6 Type designation of the flowmeter, serial number, date of manufacturing

INSTALLATION 2
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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 2-4: Transport

2INSTALLATION
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2.7 Installation conditions
2.7.1 General requirements
2.7.2 Inlet and outlet
2.7.3 Vibration
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 2-5: Recommended inlet and outlet
1 Inlet: ≥0 DN
2 Outlet: ≥0 DN
Figure 2-6: Avoid vibrations

INSTALLATION 2
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2.7.4 Mounting position and flange deviation
•Mount sensor either with converter aligned upwards or downwards.
•Install sensor in line with the pipe axis.
•Pipe flange faces must be parallel to each other.
2.7.5 T-section
Figure 2-7: Mounting position and flange deviation
1 Lmax
2 Lmin
CAUTION!
Max. permissible deviation of pipe flange faces: L
max
- L
min
≤0.5 mm / 0.2".
Figure 2-8: Distance behind a T-section
1 ≥0 DN

2INSTALLATION
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2.7.6 Magnetic field
2.7.7 Open discharge
2.7.8 Bends
Figure 2-9: Avoid magnetic fields
Figure 2-10: Installation in front of an open discharge
Figure 2-11: Installation in bending pipes

INSTALLATION 2
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2.7.9 Control valve
2.7.10 Air venting
Figure 2-12: Installation in bending pipes
Figure 2-13: Recommended installation: in front of a control valve
Figure 2-14: Air venting
1 ≥5 m
2 Air ventilation point

2INSTALLATION
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2.7.11 Pump
Figure 2-15: Installation behind a pump
1 ≥3 DN

INSTALLATION 2
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2.7.12 IP68
The WATERFLUX 3000 flow sensor is rated IP68 (NEMA 4X/6P). It is suitable for submersion in
flooded measurement chambers and for subsurface installation.
The compact IFC 070 signal converter is available in:
•an aluminium housing suitable for IP66/67, NEMA 4/4X/6
•a polycarbonate housing suitable for IP68, NEMA 4/4X/6.
This version is suitable for periodic submersion in flooded measurement chambers. The
output cable has IP68 rated (military) connectors.
In case of continuous or long term submersion it is advised to select the field (remote)
version (IP66/67). Submersion under water is possible down to a depth of 5 meters.
The remote IFC 070 signal converter is available in:
•an aluminium housing suitable for IP66/67, NEMA 4/4X/6.
Figure 2-16: IP68 versions
1 Submersible
2 Buried
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2INSTALLATION
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2.8 Mounting
2.8.1 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 2-17: Tightening of bolts

INSTALLATION 2
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Nominal size
DN [mm]
Pressure
r a t i n g
Bolts Max. torque
[Nm] 1
25 PN 16 4 x M 12 12
40 PN 16 4 × M 16 30
50 PN 16 4 × M 16 36
65 PN 16 4 × M 16 50
80 PN 16 8 × M 16 30
100 PN 16 8 × M 16 32
125 PN 16 8 × M 16 40
150 PN10 8 x M20 55
150 PN 16 8 × M 20 55
200 PN 10 8 × M 20 85
200 PN 16 12 x M20 57
250 PN 10 12 x M 20 80
250 PN 16 12 x M 24 100
300 PN 10 12 x M 20 95
300 PN 16 12 x M 24 136
1 The torque values also depend on variables (temperature, bolt material, gasket material, lubricants, etc.)
outside the control of the manufacturer. Therefore these values should be regarded as indicative only.
Nominal size
[inches]
Flange class
[lb]
Bolts Max. torque
[lbs.ft] 1
1150 4 x 1/2" 4
1½150 4 x 1/2" 11
2150 4 × 5/8" 18
2.5 150 4 x 5/8" 27
3150 4 × 5/8" 33
4150 8 × 5/8" 22
5150 8 × 3/4" 33
6150 8 × 3/4" 48
8150 8 × 3/4" 66
10 150 12 x 7/8" 74
12 150 12 x 7/8" 106
1 The torque values also depend on variables (temperature, bolt material, gasket material, lubricants, etc.)
outside the control of themanufacturer. Therefore these values should be regarded as indicative only.

2INSTALLATION
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2.9 Mounting of the field housing, remote version
2.9.1 Pipe mounting
1 Fix the signal converter to the pipe.
2 Fasten the signal converter using standard U-bolts and washers.
3 Tighten the nuts.
2.9.2 Wall mounting
No special requirements.
2.10 Mounting of the IP68 version
• Before closing the case of the converter, ensure that all surfaces in contact with the seals are
clean.
• Position the upper part of the case and tighten the lock ring.
• Use the wrench to tighten the ring as shown.
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.
Figure 2-18: Pipe mounting of the field housing
Figure 2-19: Closing of IP68 housing

ELECTRICAL CONNECTIONS 3
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3.1 Safety instructions
3.2 Grounding
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
INFORMATION!
Grounding without grounding rings. The flow sensor is equipped with a reference electrode.

3ELECTRICAL CONNECTIONS
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3.3 Connection of the signal cable
3.3.1 IP 67 housing (field version)
Dimensions of cable
CAUTION!
To ensure smooth functioning, always use the signal cables included in the delivery.
INFORMATION!
The signal cable is only used for remote versions. The standard WSC-cable includes both
electrode and field current leads.
Figure 3-2: Preparation of standard cable (both sides)
1 Shielding
2 Blue + green + yellow cable, used for field current (terminals 7, 8, 9)
3 Brown + white + violet cable, used for electrode signals (terminals 1, 2, 3)
4 Drain wires
a b c d e f
mm 75 35 70 545 30
inch 3.0 1.4 2.8 0.2 1.8 1.2
Figure 3-3: Cable connection at sensor side, standard cable
1 Connect drain wires under screw
2 Connect shielding under clamp