C-Flow KCM and KCE 5000

Manual Software-Version 1.0

Küppers Elektromechanik GmbH Quality system certified to DIN ISO 9001

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Safety and Installation Instructions

1. Appropriate Use

The measuring system described herein must only be used for the measurement of fluids and gases. The C-Flow Mass Coriolis Flow Meters measure mass flow as well as temperature and density of the measuring medium. In case of abrasive measuring media it is recommended to return the measuring system to the manufacturer after 8,000 hours of operation for re-calibration and pressure test. This interval may be shorter when the medium is extremely abrasive. 2. Duties of the User

Before installing the flow meter and transmitter the user is responsible to ensure that all wetted parts are compatible with the fluid or gas to be measured. The user should read the manual and become trained in accordance with the attached documentation. Uncertainties should be clarified with the manufacturer before start up. The user has to adhere to the instructions for installing electrical devices and corresponding instructions. 3. Installation and Operation

In accordance with this manual the user should select the installation position which fits the application best. To ensure the highest degree of accuracy and repeatability, care should be taken to affix the C-Flow products in a stable process site and minimize the amount of vibration in the installation environment. An offset procedure is recommended (see Zero-point instructions in the programming section) at initial installation of each C-Flow system. This should be done with the flow meter filled with the material to be measured and in a no-flow condition. If necessary, close valves before and after the flow meter during this procedure. C-Flow products may only be modified mechanically with the approval of the manufacturer. The devices described in this manual may only be connected and operated by authorized and qualified personnel.

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Contents

Safety and Installation page 2

Contents page 3

General page 4

Measuring Principle KCM page 5

Technical Data KCM page 6

Technical data KCE 5000 page 7

Electrical connections page 8

Dimensional drawings page 9

Installation 12

Programming the KCE page 14

KCE User Parameters page 15

Display Screens on KCE page 17

Utilizing the Magnet for Programming page 18

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General

The C-Flow Mass Coriolis measuring system consists of two components:

1 KCE Transmitter (blue or orange housing) 2 KCM Mass Coriolis Flow Meter, Transducer (grey housing) Compact versions (female inch threads or flange ends)

Separated versions (with wall- or panel-mounted transmitter)

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1. Measuring Principle KCM

Two parallel flow tubes inside the KCM flow meter are rotated at their resonant frequency by coils. Any mass flow passing through the tubes will generate coriolis forces. These forces have opposed effects on the inlet and outlet side and slightly deform the tubes. Sensors inside the flow meter measure the deformation of the tubes. The phase shift between the rotational frequencies of both tubes is proportional to the mass flow rate.

The resonant frequency of the tubes changes in accordance with the density of the medium. This effect is used to determine the density.

The extent of deformation of the pipes depends on temperature. Therefore the temperature is measured for compensation purposes.

Using only one sensor primary values as mass flow, density and temperature can be measured. Conversions allow for calculation of additional values such as volumetric flow and concentration.

Cycle of deformation (simplified) Rotation and deformation of two parallel tubes by the coriolis force Fc.

From left to right: Movement to the inside Movement to the inside and Movement to the outside Movement to the outside no flow Fc direction with flow no flow and Fc direction with flow

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2. Technical Data KCM Transducer

Type di* Measuring range kg/h Measuring Range kg/min

KCM 300 4 mm (serial) 4.5 up to 300 0.075 up to 5

KCM 600 4 mm (parallel) 9.0 up to 600 0.15 up to 10

KCM 1500 8 mm (serial) 25 up to 1,500 0.4 up to 25

KCM 3000 8 mm (parallel) 50 up to 3,000 0.9 up to 50

KCM 6000 12 mm (parallel) 60 up to 6,000 1 up to 100

KCM 20K 18 mm (parallel) 200 up to 20,000 3.3 up to 334

KCM 40K 28 mm (parallel) 400 up to 40,000 6.7 up to 667

KCM 60K 34 mm (parallel) 600 up to 60,000 10 up to 1,000 * internal tube diameter Technical Data – KCM 0300 to KCM 3000 Medium temperature: up to +125°C Connections: • female threads G1/2’’ • adapters for flanges, diary or tri-clamp connectors Operating pressure: max. 350 bar Material: stainless steel as per DIN 1.4571 (AISI 316 Ti) Ingress protection: IP 67 Electrical connection: • 9-pin flange plug • compact version with integral transmitter Max cable length: 30 metres between transducer and transmitter Ex-protection: EX II 2G EEx Exd (ib) IIC T2–T4 TPS 07 ATEX 1 282 X Weight: KCM 300 and 600: 4.1 kg KCM 1500 and 3000: 8.8 kg Technical Data – KCM 6000 to KCM 60K End connections: flanges according to EN 1092, ANSI B16.5, DIN2512 Nominal pressure: PN 40, ANSI 150/300 lbs Process temperature: –40°C to +180°C Ambient temperature: –40°C to +60°C Ingress protection: IP 65 (EN60529) (NEMA 4X) Materials flow tubes, splitter flanges: 1.4404 (316 L)/1.4571 (316 Ti) housing: cast iron

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3. Technical Data KCE 5000 Transmitter

General Display: multi-line Supply voltage: 24 VDC, ±15% Programming: via front keyboard and with magnet Interface: RS 485 or RS 232 EMC: according to EN 50 081-2 and EN 50 082-2 Power consumption: max. 2.5 W Exd housing Features: painted blue with transparent cover Connections: ½’’ female cable gland Material: aluminium diecast Protection class: IP 68 Weight: approx. 2 kg Temperature: storage and transport: 0 up to 40°C operation: –20 up to 50°C Panel-mounted housing Dimensions: 96 x 96 x 155 mm (h x w x d) Connections: rear screw terminals Protection class: front: IP 60, rear: IP 30 Weight: approx. 500 g Temperature: storage and transport: 0 up to 40°C operation: 0 up to 50°C Analog Outputs Two current outputs: 4–20 mA passive, two-wire isolated Resolution: 14 bit Linearity: ±0.05% of final value Temperature drift: 0.05% per 10 K Load: < 800 W scaled output of flow rate or job total, density or temperature Pulse Output Frequency range: 0.5–5,000 Hz Output signal: active push pull output of flow rate and/or cycle output Status In- and Output Status output: fault out info (push pull) Status input: offset start active (push pull)

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4. Electrical Connections The KCE requires 24 VDC (±15%) power. The meter-mounted housing has two conduit connections to allow wiring in and out. The conduit connections are threaded with ½’’female cable ports.

The KCE provides two passive analogue outputs, one frequency output, RS-485/RS232 serial communication and status in and out connections. Shown below are the connection terminals.

KCE 5000 blue Exd housing – view of electrical connections with rear hub removed KCE 5000 orange panel-mounted housing rear side

KCE Terminal connections

1 + mA (1) Two-wire 24 VDC passive 2 – mA (1) 3 + mA (2) Two-wire 24 VDC passive 4 – mA (2) 5 Frequency out 6 Status out/Alarm out, used as fault output, signal: push pull output max. 20 mA 7 Status in/Ext. zero, used for external offset 8 GND Ground (for pins 5 through 7)

20 COM Common (applies only to RS485/RS232) 21 -RS485/RS232 22 +RS485/RS232

50 +24 VDC 51 -VDC (also used as reference for pins 5, 6 and 7) 52 PE (earth ground)

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5. Dimensional Drawings (mm) KCM 0300 to KCM 3000

Type a b c d e f

KCM 0300 214 182 160 15 19 110 KCM 0600 214 182 160 15 19 87 KCM 1500 350 280 258 18 21 140 KCM 3000 350 280 258 18 21 140

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KCM 6000 to KCM 60K

Type a b c f g flange ends

KCM 6000 400 465 173 65 113 DN 25 PN 40, ANSI 1” 150/300 lb

KCM 20K 500 506 206 65 113 DN 50 PN 40, ANSI 2” 150/300 lb

KCM 40K 600 592 290 77 137 DN 80 PN 40, ANSI 3” 150/300 lb

KCM 60K 600 592 290 77 137 DN 80 PN 40, ANSI 3” 150/300 lb

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KCM with wall-mounted housing

Type a b c d e F

KCM 0300 214 182 160 15 19 110 KCM 0600 214 182 160 15 19 87 KCM 1500 350 280 258 18 21 140 KCM 3000 350 280 258 18 21 140

Panel-mounted housing

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6. Installation 6.1 Horizontal Installation When the KCM is installed horizontally the exact position depends on the measuring medium. The KCM housing should point upward (A) when the fluid contains solids. This will help avoid deposits in the measuring tube. The KCM housing should point downward (B) when the fluid contains gas or air bubbles. This will help avoid falsified measurements due to gas bubbles.

6.2 Vertical Installation A vertical installation should only be selected, if a) the medium contains no deposits. b) gas or air bubbles are not expected. When the KCM is installed vertically the flow direction should be upward. Please consider that the KCM will not run empty in this position due to the geometric construction of the measuring tubes.

Important notes on vertical installation When the system is stopped gas or air bubbles may accumulate at the highest point of the tubes. Due to the tube geometry the measuring tubes do not vent automatically in vertical installation position. Gas bubbles may also accumulate at the highest point of the tubes when the mass flow is very low. Generally, gas bubbles will lead to undefined measuring results due to the big density difference.

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6.3 Installation in a Drop Line This installation requires a pipe reduction or orifice with a smaller cross section than the KCM to ensure the KCM cannot drain during the measuring process.

6.4 Critical Installations Installations which may lead to an inclusion of air or gas bubbles should be avoided as the might falsify the measuring results considerably. Therefore installations at the highest point of the system (A) or close upstream of a free discharge (B) are not recommendable.

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7. Programming the KCE The KCE can be programmed by removing the front cover and using the four buttons on the front panel. Blue Exd versions may also be programmed utilizing the magnet attached to the housing with the cover left in place. The cover must not be reomoved within the hazardous area (please see UTILIZING THE MAGNET FOR PROGRAMMING section later in this manual). To access the programming mode, press and hold the PRG button for three seconds. The display will show 2206 and ask for entry of the user code. The user code is 2207. Press the UP/INFO button (top left) to increment the number to 2207. Press the PRG button (top right). The display will show OKAY for one second, then display FLOW-UNITS, the first of 18 user-programmable parameters.

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8. KCE User Parameters (in order)

FLOW-UNITS FLOW-DP FLOW-FILTER TOTAL-UNITS TOTAL-DP DENS-UNITS TEMP-DIM KEY-RESET FLOW-DIREC FREQ-OUT CURRENT-1 CURRENT-2 ZERO-POINT DISPLAY FAULT TIME SAVE DATA RESTORE DAT SIMULATION

Functions of the keys

to advance through the list of parameters.

to start programming the displayed parameter and save changes.

and to change the entered value for the parameter.

to exit without saving changes.

Following is a description of the KCE programming parameters:

FLOW-UNITS: This feature determines the units used to display flow rate. User may choose from a list of engineering units, including pound, kilogram and gram per second, minute and hour.

FLOW-DP: Determines the decimal place used in the flow rate display.

FLOW-FILTER: Used to dampen the display. Bigger numbers result in a smoother, less noisy flow display.

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TOTAL-UNITS: Determines the units used in the flow total display.

TOTAL-DP: Determines the decimal place used in the flow total display.

DENS-UNITS: Allows user to choose various units for the density display.

TEMP-DIM: Temperature can be displayed in degrees Fahrenheit or Celcius.

KEY-RESET: When this function is turned on, user can reset the flow totalizer by pressing the RIGHT button. When this function is turned off, the totalizer will only be reset when power to the transmitter is cycled.

FLOW-DIREC: Although the KCM Mass Coriolis Flow Meters are calibrated in one direction and an arrow is placed on the label indicating the preferred direction of operation, the user can program the transmitter to run in the reverse direction by accessing this parameter.

FREQ-OUT: The user can change Frequency or Cycle Out options in this parameter. In Frequency, the user can program the flow rate that they want to equal 1000 hertz. Cycle Out should be set to 0. CURRENT-1: User can select the information for this output (flow rate, density, temperature or 4 mA output) scale the output, set the offset for the output and set the filter for the output.

CURRENT-2: Same functions as CURRENT 1 but for the second mA output.

ZERO-POINT: This peforms the offset for the mass coriolis flow meter. An offset should be done at initital installation and if ambient conditions change

DISPLAY: Determines how the display will appear. Options include what measurement units are displayed and whether the display is shown in one or two lines.

FAULT TIME: Determines how long to display a fault signal and how quickly the unit should respond to a fault.

SAVE DATA: Parameters are saved in the unit by performing this function. If the save is successful, the unit will display READY.

RESTORE DAT: This restores factory settings. DO NOT USE WITHOUT CONSULTING FACTORY.

SIMULATION: Unit can simulate flow conditions by giving signals on the frequency, Current 1, Current 2, Status Out and RS485 outputs.

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9. Display Screens on the KCE The KCE can show two separate two line displays of process data.

To toggle between the two separate displays, press and hold the ENT button (bottom right) for one second. The same command can be executed with the magnet (please see instructions on next page).

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10. Utilizing the Magnet for Programming

The KCE can be programmed by removing the front cover and using the four buttons on the front panel or by leaving the front cover in place and utilizing the magnet attached to the housing. This is absolutely necessary within hazardous areas.

To use this feature, touch the magnet on the outside of the housing in the appropriate quadrants (ENT, PRG, UP and RIGHT) of the four function buttons. Touch the magnet about 1.25 inches back of the front surface with the magnet on its side. Please see the illustration below for an example of proper placement of magnet. The magnet should be laid on its side and touched to the side of the housing. Please note several of the programming functions require several seconds to initiate.

The magnet allows the user to perform programming and other functions while the KCE is in a hazardous environment or any time the user would prefer to keep the housing intact.

Subject to change without notice. Copyright KEM Rev. 002/05/07