BATCHFLUX 5500 C Handbook

Electromagnetic flowmeter for volumetric filling

machines

© KROHNE 03/2010 - 4000827701 - HB BATCHFLUX 5500 R01 en

: IMPRINT ::::::::::::::::::::::::::::::::::

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.

Copyright 2010 by
KROHNE Messtechnik GmbH - Ludwig-Krohne-Str. 5 - 47058 Duisburg (Germany)

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 BATCHFLUX 5500 C CONTENTS

1 Safety instructions 5

1.1 Intended use ..................................................................................................................... 5

1.2 Safety instructions from the manufacturer ..................................................................... 5
1.2.1 Disclaimer ............................................................................................................................... 5
1.2.2 Information concerning the documentation........................................................................... 6
1.2.3 Warnings and symbols used................................................................................................... 7
1.3 Safety instructions for the operator................................................................................. 7

2 Device description 8

2.1 Scope of delivery............................................................................................................... 8

2.2 Visual check...................................................................................................................... 8

3 Installation 9

3.1 Notes on installation ........................................................................................................ 9

3.2 Storage ............................................................................................................................. 9
3.3 Installation conditions ...................................................................................................... 9
3.3.1 Inlet and outlet ........................................................................................................................ 9
3.3.2 Mounting position.................................................................................................................. 10
3.3.3 Hot filling............................................................................................................................... 10
3.3.4 Horizontal pipe run ............................................................................................................... 11
3.3.5 Control valve ......................................................................................................................... 11
3.3.6 Pump ..................................................................................................................................... 11
3.3.7 Open feed or discharge......................................................................................................... 12
3.3.8 Installation location .............................................................................................................. 12
3.3.9 Flange deviation .................................................................................................................... 13
3.3.10 Grounding............................................................................................................................ 13

4 Electrical connections 14

4.1 Safety instructions.......................................................................................................... 14

4.2 Electrical connection...................................................................................................... 14

5 Service 16

5.1 Spare parts availability................................................................................................... 16

5.2 Availability of services .................................................................................................... 16
5.3 Returning the device to the manufacturer..................................................................... 16
5.3.1 General information.............................................................................................................. 16
5.3.2 Form (for copying) to accompany a returned device............................................................ 17
5.4 Disposal .......................................................................................................................... 17

6 Technical data 18

6.1 Measuring principle........................................................................................................ 18

6.2 Technical data................................................................................................................. 19

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 CONTENTS BATCHFLUX 5500 C

6.3 Temperatures ................................................................................................................. 23

6.4 Dimensions and weights ................................................................................................ 24
6.5 Counter Flanges ............................................................................................................. 27

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 BATCHFLUX 5500 C SAFETY INSTRUCTIONS 1

1.1 Intended use

The electromagnetic flowmeter is designed exclusively for measuring the volumetric flowrate of
electrically conductive, liquid process products.

Needed electrical conductivity for products:

• > 5 µS/cm (except for water)
• > 20 µS/cm (for water)

1.2 Safety instructions from the manufacturer

1.2.1 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.

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1 SAFETY INSTRUCTIONS BATCHFLUX 5500 C

1.2.2 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.

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 BATCHFLUX 5500 C SAFETY INSTRUCTIONS 1

1.2.3 Warnings and symbols used

Safety warnings are indicated by the following symbols.

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!
This warning refers to the immediate danger when using this device in a hazardous atmosphere.

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.

• HANDLING
This symbol designates all instructions for actions to be carried out by the operator in the
specified sequence.
i RESULT
This symbol refers to all important consequences of the previous actions.

1.3 Safety instructions for the operator

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.

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2 DEVICE DESCRIPTION BATCHFLUX 5500 C

2.1 Scope of delivery

Figure 2-1: Scope of delivery

1 Flowmeter in ordered size
2 Product documentation
3 CD-ROM with product documentation

2.2 Visual check

Figure 2-2: Visual check

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 for the correct supply voltage printed on the nameplate.

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 BATCHFLUX 5500 C INSTALLATION 3

3.1 Notes on installation

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 for the correct supply voltage printed on the nameplate.

3.2 Storage
• Store the device in a dry and dust-free location.
• Avoid lasting direct exposure to the sun.
• Store the device in its original packing.

3.3 Installation conditions

3.3.1 Inlet and outlet

Figure 3-1: Inlet and outlet section

1 ≥ 5 DN
2 ≥ 2 DN

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3 INSTALLATION BATCHFLUX 5500 C

3.3.2 Mounting position

Figure 3-2: Installation in bending pipes

CAUTION!
Avoid draining or partial filling of the flow sensor.

WARNING!
Vertical down position only in conjunction of a control valve

3.3.3 Hot filling

Figure 3-3: Installation position with heated pipes

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 BATCHFLUX 5500 C INSTALLATION 3

3.3.4 Horizontal pipe run

Figure 3-4: Horizontal piperun

CAUTION!
Install in a slightly descending pipe section to prevent air from collecting and to avoid faulty
measurements (meter can drain).

3.3.5 Control valve

Figure 3-5: Installation before control valve

3.3.6 Pump

Figure 3-6: Installation after pump

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3 INSTALLATION BATCHFLUX 5500 C

3.3.7 Open feed or discharge

Figure 3-7: Installation before an open discharge

3.3.8 Installation location

Figure 3-8: Installation location

CAUTION!
Mount the flow sensor in such a way that the electrode axis
(X--------X) is approximately in a horizontal pipe run.

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 BATCHFLUX 5500 C INSTALLATION 3

3.3.9 Flange deviation

Figure 3-9: Mounting position and flange deviation

1 Lmax
2 Lmin

CAUTION!
Max. permissible deviation of pipe flange faces:
Lmax - Lmin ≤ 0.5 mm / 0.02"

3.3.10 Grounding

CAUTION!
The grounding wire should not transmit any interference voltage. Therefore do not ground any
other electrical device at the same conductor.

CAUTION!
When connecting to functional extra-low voltages (24VDC) , ensure that you use protective
separation (PELV) according to IEC 364/IEC 536 or VDE 0100/VDE 0106.

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4 ELECTRICAL CONNECTIONS BATCHFLUX 5500 C

4.1 Safety instructions

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.

4.2 Electrical connection

2
3
5
1
4

1 +24 VDC
2 Frequency output
3 Frequency output (ground)
4 Ground
5 BATCHMon Plus, for service / parameter settings

CAUTION!
Use only a 4 wire cable (Pin 1 to 4)

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 BATCHFLUX 5500 C ELECTRICAL CONNECTIONS 4

Use one of the following attachment plug types to connect the flowmeter to a third
party system:
• moulded plug, straight or angle-entry form
• integrally extruded plug with cable in various lengths
• moulded plug, straight form, especially suitable for high-interference environments

Possible vendors of these plugs are:

• Binder
• Hirschmann
• Lumberg
• Amphenol
• Coninvers

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5 SERVICE BATCHFLUX 5500 C

5.1 Spare parts availability

The manufacturer adheres to the basic principle that functionally adequate spare parts for each
device or each important accessory part will be kept available for a period of 3 years after
delivery of the last production run for the device.

This regulation only applies to spare parts which are under normal operating conditions subjects
to wear and tear.

5.2 Availability of services

The manufacturer offers a range of services to support the customer after expiration of the
warranty. These include repair, technical support and training.

INFORMATION!
For more precise information, please contact your local representative.

5.3 Returning the device to the manufacturer

5.3.1 General information
This device has been carefully manufactured and tested. If installed and operated in accordance
with these operating instructions, it will rarely present any problems.

CAUTION!
Should you nevertheless need to return a device for inspection or repair, please pay strict
attention to the following points:
• Due to statutory regulations on environmental protection and safeguarding the health and
safety of our personnel, manufacturer may only handle, test and repair returned devices that
have been in contact with products without risk to personnel and environment.
• This means that the manufacturer can only service this device if it is accompanied by the
following certificate (see next section) confirming that the device is safe to handle.

CAUTION!
If the device has been operated with toxic, caustic, flammable or water-endangering products,
you are kindly requested:
• to check and ensure, if necessary by rinsing or neutralizing, that all cavities are free from
such dangerous substances,
• to enclose a certificate with the device confirming that is safe to handle and stating the
product used.

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 BATCHFLUX 5500 C SERVICE 5

5.3.2 Form (for copying) to accompany a returned device

Company: Address:

Department: Name:

Tel. no.: Fax no.:

Manufacturer's order no. or serial no.:

The device has been operated with the following medium:

This medium is: water-hazardous

toxic
caustic
flammable
We checked that all cavities in the device are free from such
substances.
We have flushed out and neutralized all cavities in the
device.

We hereby confirm that there is no risk to persons or the environment through any residual media
contained in the device when it is returned.

Date: Signature:

Stamp:

5.4 Disposal
CAUTION!
Disposal must be carried out in accordance with legislation applicable in your country.

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6 TECHNICAL DATA BATCHFLUX 5500 C

6.1 Measuring principle

An electrically conductive fluid flows inside an electrically insulating pipe through a magnetic
field. This magnetic field is generated by a current, flowing through a pair of field coils. Inside of
the fluid, a voltage U is generated:
U=v*k*B*D

in which:
v = mean flow velocity
k = factor correcting for geometry
B = magnetic field strength
D = inner diameter of flow meter

The signal voltage U is picked off by electrodes and is proportional to the mean flow velocity v
and thus the flow rate q. The signal voltage is quite small (typically 1 mV at v = 3 m/s / 10 ft/s and
field coil power of 1 W). Finally, a signal converter is used to amplify the signal voltage, filter it
(separate from noise) and convert it into signals for totalising, recording and output processing.

1 Induced voltage (proportional to flow velocity)

2 Electrodes
3 Magnetic field
4 Field coils

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 BATCHFLUX 5500 C TECHNICAL DATA 6

6.2 Technical data

INFORMATION!
• The following data is provided for general applications. If you require data that is more
relevant to your specific application, please contact us or your local representative.
• Additional information (certificates, special tools, software,...) and complete product
documentation can be downloaded free of charge from the website (Download Center).

Measuring system
Measuring principle Faraday's law
Application range Electrically conductive fluids
Measured value
Primary measured value Flow velocity
Secondary measured value Volume flow

Design
Features Tube: Zirconium oxide (DN2.5...15) / Aluminium oxide (DN25...40)
Electrodes: Fused-in cermet (DN2.5...15) / Platimum (DN25...40)
Standard wet calibration
Modular construction The measurement system consists of a flow sensor and a signal
converter. It is only available as compact version.
Compact version BATCHFLUX 5500 C
Nominal diameter DN2.5...40 / 0.1...1½"
Measurement range -12...+12 m/s / -39...+39 ft/s
User interface
Operating data Factory set to customer specification.
Human Machine Interface (HMI) Option: BATCHMon Plus software
Cable connections 1x M12, 5-pin connector

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6 TECHNICAL DATA BATCHFLUX 5500 C

Measuring accuracy
Reference conditions Medium: water
Inlet / outlet section: 10 DN / 5 DN
Valve closing time variation: < 1 ms
Flow velocity: 1 m/s, flow conditions similar to EN 29104
Operating pressure: 1 bar / 14.5 psi
Error limits at reference conditions for tap water, 400 µS/cm,
S/cm, 20°C
20 C / 68°F
68 F:
Maximum measuring error DN2.5...6:
v ≤ 1 m/s: ±0.4% of measured value + 1 mm/s
v > 1 m/s: ±0.5% of measured value
DN10...15:
±0.2% of measured value + 1 mm/s
DN25...40:
v ≤ 1 m/s: ±0.2% of measured value + 1 mm/s
v > 1 m/s: ±0.3% of measured value
Repeatability DN2.5...6 / DN25...40: Standard deviation:
Filling time 1.5...3 s: ≤ 0.4%
Filling time 3...5 s: ≤ 0.2%
Filling time > 5 s: ≤ 0.1%
DN10...15: Standard deviation:
Filling time 1.5...3 s: ≤ 0.3%
Filling time 3...5 s: ≤ 0.15%
Filling time > 5 s: ≤ 0.08%
Error limits at reference conditions for hot water, 400 µS/cm,
S/cm, 80°C
80 C / 176°F
176 F:
Maximum measuring error DN10...15:
±0.2% of measured value + 1 mm/s
Repeatability DN10...15: Standard deviation:
Filling time 1.5...3 s: ≤ 0.3%
Filling time 3...5 s: ≤ 0.2%
Filling time > 5 s: ≤ 0.1%

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 BATCHFLUX 5500 C TECHNICAL DATA 6

Operating conditions
Temperature
Process temperature Dependent of ambient temperature. See chapter "Temperatures".
Cleaning temperature SIP: Maximum 1 hour at 150°C / +302°F
CIP: Maximum 1 hour at 140°C / +284°F
Shock ≤ 3 K/s
Ambient temperature -40…+60°C / -40…+140°F
Storage temperature -50…+70°C / -58…+158°F
Pressure
Ambient Atmospheric
Process pressure up to 16 bar / 232 psi for DN10...15
up to 40 bar / 580 psi for DN2.5...6 / DN25...40
Vacuum load 0 mbara / 0 psig
Chemical properties
Physical condition Liquids
Electrical conductivity ≥ 5 μS/cm (≥ 20 μS/cm for demineralised water)
Recommended flow velocity -12...+12 m/s / -39...+39 ft/s

Installation conditions
Installation For detailed information see chapter "Installation".
Inlet run ≥ 5 DN
Outlet run ≥ 2 DN
Dimensions and weights For detailed information see chapter "Dimensions and weights".

Materials
Sensor housing Stainless steel 1.4404 / 1.4408
Converter housing Stainless steel 1.4404 / 1.4408
Measuring tube Fused in-place
Measuring electrodes DN2.5...15: Cermet
DN25...40: Platinum

Process connections
Connection Sandwich design
Optional: Pressure relief groove at flange facing of the sensor
Construction drawings of counter flanges available from download
centre.

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6 TECHNICAL DATA BATCHFLUX 5500 C

Electrical connections
Power supply 24 VDC ± 25%
Please use a 4 wire cable when wiring the M12 plug.
Power consumption ≤3W
Switch on current ≤ 5 A (< 100 μs) at 24 VDC
Voltage loss Possible for a maximum of 20 ms according to NAMUR NE21.
BATCHMON Plus For parameter setting and diagnostic purposes, communication via
PC with a single device (optional)
Frequency output
Type Frequency (passive) / galvanically isolated from power supply
Function All operating data preset at factory.
Interval Counter gate time ≥ 1000 / (P100% [Hz])
Frequency output ≤ 10 kHz
Pulse width at full scale value ≤ 10 Hz: 50, 100, 200 or 500 ms
> 10 Hz: automatic, pulse width = 1 / (2 x f100%) or symmetrical, 1:1
Passive operation Connection of electronic or electromechanical counters.
External voltage: ≤ 30 VDC / ≤ 24 VAC
Load: Imax ≤ 20 mA
Low flow cut-off Threshold: 0...20%
Hysteresis: 0...20%
Hysteresis ≤ threshold

Approvals and certifications

CE
This device fulfills the statutory requirements of the EC directives.
The manufacturer certifies successful testing of the product by
applying the CE mark.
Electromagnetic compatibility Directive: 2004/108/EC
Harmonized standard: EN 61326-1: 2006
Low voltage directive Directive: 2006/95/EC
Harmonized standard: EN 61010: 2001
Pressure equipment directive Directive: 97/23/EC
Category SEP
Fluid group 1
Production module H
Other approvals and standards
Protection category acc. to DN2.5...6 / DN25...40: IP 66/67
IEC 529 / EN 60529
DN10...15: IP 69K
Shock- and vibration resistance IEC 68-2-3
Hygienic DN2.5...15: 3A
FDA approved materials

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6.3 Temperatures
Process temperature vs ambient temperature

1 Ambient temperature
2 Process temperature

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6 TECHNICAL DATA BATCHFLUX 5500 C

6.4 Dimensions and weights

DN2.5...6

Figure 6-1: Dimensions

1 M5
2 5 pins connector

Nominal Dimensions [mm] Weight

size [kg]
a b c d e f g h i
DN2.5 50 156 206 6 → 2.5 44 88 141 128 54 1.5
DN4 50 156 206 7 → 3.2 44 88 141 128 54 1.6
DN6 50 156 206 9 → 4.8 44 88 141 128 54 1.6
Note on dimension d: As the diameter reduces to the middle, the diameter is specified for the inlet and
for the middle

Nominal Dimensions [inches] Weight

size [lb]
a b c d e f g h i
1/10" 1.97 6.14 8.11 0.24 → 0.10 1.73 3.46 5.55 5.0 2.13 3.4
1/6" 1.97 6.14 8.11 0.28 → 0.13 1.73 3.46 5.55 5.0 2.13 3.6
1/4" 1.97 6.14 8.11 0.35 → 0.19 1.73 3.46 5.55 5.0 2.13 3.6
Note on dimension d: As the diameter reduces to the middle, the diameter is specified for the inlet and
for the middle

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 BATCHFLUX 5500 C TECHNICAL DATA 6

DN10...15

1 M5
2 5 pins connector

Nominal Dimensions [mm] Weight

size [kg]
a b c d e f g h i
DN10 50 140 179 10.5 → 8 45.4 60 106.5 88 54 1.4
DN15 50 140 179 14 → 12 45.4 60 106.5 88 54 1.4
Note on dimension d: As the diameter reduces to the middle, the diameter is specified for the inlet and
for the middle

Nominal Dimensions [inches] Weight

size [lb]
a b c d e f g h i
3/8" 1.97 5.51 7.05 0.41 → 0.31 1.79 2.36 4.19 3.46 2.13 3.09
1/2" 1.97 5.51 7.05 0.55 → 0.47 1.79 2.36 4.19 3.46 2.13 3.09
Note on dimension d: As the diameter reduces to the middle, the diameter is specified for the inlet and
for the middle

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6 TECHNICAL DATA BATCHFLUX 5500 C

DN25..40

Figure 6-2: Dimensions

1 M5
2 5 pins connector

Nominal Dimensions [mm] Weight [kg]

size
a b c d e f g h i
DN25 50 170 204 26 → 20 68 102 141 128 58 1.6
DN40 50 177 219 39 → 30 84 117 141 128 83 2.3
Note on dimension d: As the diameter reduces to the middle, the diameter is specified for the inlet and
for the middle

Nominal Dimensions [inches] Weight [lb]

size
a b c d e f g h i
1" 1.97 6.69 8.03 1.02 → 0.79 2.68 4.02 5.55 5.04 2.28 3.6
1 1/2" 1.97 6.97 8.62 1.54 → 1.18 3.30 4.61 5.55 5.04 3.27 5.1
Note on dimension d: As the diameter reduces to the middle, the diameter is specified for the inlet and
for the middle

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 BATCHFLUX 5500 C TECHNICAL DATA 6

6.5 Counter Flanges

The BATCHFLUX 5500 can be mounted between various types of counter flanges.

1 2

Sizes of flanges
a [mm] b [mm] c [mm] d [mm] O-ring
Flange 1 Ø 14.2 Ø 18.5 Ø 23 Ø 30.4 Special L-ring
Flange 2 Ø 14.2 Ø 19.2 Ø 26.6 Ø 30.4 15.47 * 3.53
Flange 3 Ø 14.2 Ø 15.8 Ø 24 Ø 30.4 15.47 * 3.53

INFORMATION!
Detailed construction drawings of the above sketches are available from the download centre

INFORMATION!
The O-rings require periodic replacement. As the interval depends on process-specific
variables, the length of the interval cannot be specified.
The O-rings are not part of the portfolio of KROHNE.

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 KROHNE product overview
• Electromagnetic flowmeters
• Variable area flowmeters
• Ultrasonic flowmeters
© KROHNE 03/2010 - 4000827701 - HB BATCHFLUX 5500 R01 en - Subject to change without notice.

• Mass flowmeters
• Vortex flowmeters
• Flow controllers
• Level meters
• Temperature meters
• Pressure meters
• Analysis products
• Measuring systems for the oil and gas industry
• Measuring systems for sea-going tankers

Head Office KROHNE Messtechnik GmbH

Ludwig-Krohne-Str. 5
D-47058 Duisburg (Germany)
Tel.:+49 (0)203 301 0
Fax:+49 (0)203 301 10389
[email protected]
The current list of all KROHNE contacts and addresses can be found at:
www.krohne.com