Flomag 3000 Owner's manual

FLOMAG s.r.o.

V Aleji 180/20a

CZ-620 00 Brno

Czech Republic

tel: +420 541212539

fax: +420 549240356

e-mail: info@flomag.com

www.flomag.com

Magnetic Flowmeter

LOMAG®3000

Installation and Operation

FLOMAG 3000 - Installation and Operation Manual

An magneticflowmeter isused

for volumeflowmeasurement of

electricallyconductiveliquids.

Measurement principleisbased

on Faradaylawon electromag-

neticinduction. Asensor con-

sistsofanon-magnetictube

withnon-conductivelining,

measuring electrodesandtwo

coilsgenerating electromag-

neticfield.Flowingliquidforms

aconductor. Magneticfieldin-

ducesvoltage Uinthisconduc-

tor that isproportionalto mag-

neticinduction B,distancebe-

tween electrodes dandflow

velocity v.

U =Bx d xv

Asmagneticinduction anddis-

tance between electrodesare

constant, induced voltage is

proportionaltovelocityofliquid

flowinthe tube. Volume flow

rate isproductofflowvelocity

and tubecross section.

Q=vx S Fig.1 - Principle ofmeasurement

Principle of measurement

Technical solution

The magneticflowmeter itself

consistsoftwobasicparts–a

flow sensor andaconverter.

The converter can beeither an

integralpart ofthe sensor

(compactversion) or separated,

connectedwiththesensorus-

ing a cable (remote version).

The sensor consistsofanon-

magnetictube with non-

conductivelining, measuring

electrodes,excitationcoilsand

cables.There are varioussen-

sor versionsavailableenabling

connectiontoadjacent tubes

with flanges(type P)and fittings

(gasfitting type Gorfood indus-

tryfittingtype V)or wafer which

are installedbetweenflanges

using clamps(type B). Non-

conductivelining can be made

oftechnicalrubber (types TG,

MG or NG) or Teflon (type T).

The converter isusedfor gener-

atingexcitation current incoils,

processing ofsignalfrommeas-

uring electrodes,displayingof

measured data andgenerating

output signals.Current inexci-

tation coilshasconstant value

250 mAor 125 mAand ispulse

generated with alternatingpo-

larityto avoidpermanent mag-

netizationofthesensor.Excita-

tionpulsefrequencycanbe

chosen fromsixvalues–25Hz,

12,5Hz,8,33 Hz,6,25Hz,

3,125Hzand1,56Hz.Excita-

tion currentof250 mAwithex-

citation frequency3,125 Hzis

suitablefor allstandard applica-

tions.Othersettingscanbe

used for specificapplications.

Excitation current andfre-

quencyarefactorysetbefore

sensor calibrationandtheirlater

modificationsare notallowed.

Voltageinducedinmeasuring

electrodesismeasured always

on theendofexcitation pulse

whenmagneticfieldissteady.

Eachexcitationpulseisfol-

lowedbyrefreshingperiod.Sig-

nalprocessing andparameter

settingare performed digitally

and theconverter contains no

settingcontrolsor othermoving

partswhatensuresitshighreli-

abilityand long-termstability.

-I

1/8T 3/8T

1/8T

Fig. 2- Excitation pulse form

FLOMAG 3000 - Installation and Operation Manual

min 5 x DN min3 x DN

The flowmeter will givethebest

resultswhen flowofliquidis

steady.Therefore afewbasic

recommendationsshould be

observedfor itslocating ina

pipeline.There shouldbeno

transitionsbetweenthesensor

and the adjacent pipelinethat

couldbe asource ofturbulence.

Correctaxialalignment should

be observed duringinstallation.

Agasket shouldnotexceed

internaledgesoftubes.

Ifmore interfering elementsare

present near the sensor (e.g.

bends, fittings), required steady

length should be multiplied by

number ofthese interfering ele-

ments.

Reductionswith slopesup to 8°

can be includedinsteady

lengths.

Minimumstraightsteady

lengthsofpipelinearerequired

on bothsidesofthe flow sen-

sor. Theirlengthshavetobe

proportionalto pipelineinternal

diameter.

Fig. 3- Overlaps

Fig.4 - Steadylengths

8°max

max45°

min 2 xDN

Fig.5 - Reduction

Ifwater inthepipelineis

pumped byawaterpump, the

sensor shouldbealwayslo-

cated behindthepumpto avoid

lowpressure thatcan damage

the sensor. Steadylength ofat

least25DNisrequiredbetween

the pump and the sensor.

Fig. 6- A water pump

For the samereason,never

locatestopvalvesbehindthe

sensor.

Fig. 7- Stop valves

The sensor can workboth in

horizontaland verticalpositions;

onlyaxisofmeasuring elec-

trodesinsidethe sensor must

alwaysremaininhorizontalpo-

sitionandtapping ofthe sensor

shouldbedirectedupwardsat

horizontalinstallations.

Fig. 8- Electrode axis

For verticalinstallations,liquid

should flowupwards.

Fig. 9- Verticalinstallation

Toensure correct measurement

and to avoidairlock,whole

sensor cross section shouldbe

flooded.Therefore never locate

the sensor inupper partsof the

pipelineor inverticalpositions

with liquid flowing downwards.

Fig.10 - Danger ofair lock

Ifpermanent flooding ofwhole

pipeline cross section cannot be

ensured, itispossibleto locate

the sensor inalowwatertrap

sothat itcan be alwayscom-

pletelyflooded. Freewaterdis-

charge shouldbe located2DN

higher than the sensor.

Fig.11 - Permanent flooding

Toavoidvibrationsthat could

damage the sensor, ensurethat

the adjacent pipelineisalways

supportedasnear tothesensor

aspossible.

Fig.12 - Danger ofvibrations

Where continuousflowoffluid

isrequiredandremovalof the

sensor isimpossible, abypass

shouldbeinstalled. Thesame

appliesfor locationswheresen-

sor removalwouldrequire

drainingoftoolongpart of the

pipeline.

Fig. 13 - Abypass

Installation instructions

FLOMAG 3000 - Installation and Operation Manual

Correct function ofthe magnetic

flowmeter requiresperfectelec-

tricalconnection betweenthe

sensor and theadjacent pipe-

line, grounding potentialand the

power supplyprotectivewire.

For the flanged sensor withthe

adjacent conducting pipeline,

flangesshouldbe electrically

connectedandthepipeline

grounded.

Ifthe adjacent pipelineis

non-conductive, groundingrings

shouldbe inserted initor

equivalent method shouldbe

Fig.16: Grounding rings

Fig.17. The wafer sensor

Fig.18: Cathodicprotection

Fig.15: Grounding offlanges

connection ofsensor clamping

flangeswithgrounding point of

the sensor.

Ifelectriccurrent flowsthrough

the pipeline,e.g.for pipeline

cathodicprotectionagainstcor-

rosion,thesensorshouldbe

electricallyisolatedfromthe

adjacent pipeline. The sensor

shouldbe bridged over using a

wire andgalvanicisolationof

the flowmeter power supply

shouldbeprovided so thatthe

flowmeter canbeisolatedfrom

allother devices.

Sensor grounding

Selection of suitable sensor lining and electrode material

Linings

Sensorshaveanon-conductive

liningfromvariousmaterials.

Choice ofmaterialdepends on

measured fluid characteristics.

· Technical rubber

Technicalrubber issuitablefor

lowaggressivefluidswithop-

erationaltemperaturesfrom0.1

°C to70°C.It fitsfor mostwa-

ter management andsewage

treatment applications.Itis

manufactured intwovariants

“TG” –with hard structureand

“MG” –withsoftstructure.Soft

structure isusedfor fluidswith

higher content ofabrasiveparti-

cles(e.g.sand). It isnotsuit-

able for drinking water.

· Resistant rubber

Type “NG” issuitablefor me-

diumaggressivefluidswithop-

erationaltemperaturesfrom0.1

°C to 90°C.It can be usedfor

measurement ofhot service

water, condensate etc., aswell

asfor drinking water. Iftem-

perature100 °C canbeex-

ceeded,Teflon (PTFE) lining is

recommended.

· Teflone or Hallar

Type “T” isthe mostuniversal

liningfor aggressivefluidswith

operationaltemperaturesfrom-

20 °Cto 150°C. It issuitable for

chemicalandfood industryap-

plications.

Electrodes

Choiceofmaterialofmeasuring

electrodesalsodependson

measured fluid characteristics.

· Stainless steel – “Ss”

Standardelectrodesaremade

ofstainless steelAISI 316Ti.

Theyare suitablefor allusual

water basedfluidsandfor lower

concentrationsofacidsand

caustics.

· Hastelloy C-22 – “Ha”

For somespecialapplications,

materialofhigher qualityshould

be used. HastelloyC-276 elec-

trodesare characterized byin-

creased resistanceagainstac-

idsand caustics and usuallyare

suitablefor mostofindustrial

applications.

· Titanium - „Ti“

Suitablefor someacids,

lyes,chlorine, urea and sew-

age.

· Platinum –“Pt”

For particularlyaggressiveflu-

idslikeconcentrated acidsand

caustics,chemicallyextremely

resistant materialshouldbe

chosen –platinum.However,

highcostofthismaterialis its

essentialdrawback.

*Note –Wecan recommend

suitableliningand electrode

materialsfor your particularap-

plication.

used to connectmeasuredfluid

electricalpotentialwithground.

For the wafer sensor, grounding

can be provided byelectrical

FLOMAG 3000 - Installation and Operation Manual

Converter iscapableto detect

flowratesaslowas0.1m/s.

Upper limitisdeterminedby

capabilityofliquidto maintain

continuousflowat higher veloci-

ties.Thisisusuallytrue forflow

ratesup to 12 m/s.

Measurement errorrapidly

increasesfor toolowflowrates,

ascan beseeninthediagram.

It showslimitsofmaximumrela-

tivemeasurement error asfunc-

tionofliquid flowrate.

Onthe other side, too high

flowratecausesdiscontinuityof

flowandresultsinchaotictur-

bulenceandvacuum traps.This

resultsininstablemeasurement

and toohigh driftofflow rate

values.

Idealoperationalrangeofthe

sensor isinrangefrom0.5 to 5

m/s.Thisrange ishighlighted in

the diagramfor correctsizese-

lection.

Flowrate rangesfor individual

sizesare chosento meet EN

14154standard and theyare

shownintable.Preferred

rangesare highlighted inbold.

For non-specifiedworkingme-

ters,other range can be also

specified on request.

Ifrange isnot specified ina

purchase order, the sensor will

be calibrated inpreferred range

in accordancewith the table

above.

Correct sensor size selection

0.1

Flow velocity [ m/s ]

Volumeflow rate

10 2 3 4 5 10 2 3 4 5 10 2 3 4 5 10 2 3 4 5 10 2 3 4 5 10

-2 -1 023

DN 10

DN 20

DN 25

DN 32

DN40

DN 50

DN 65

DN 80

DN100

DN 125

DN150

DN 15

DN200

DN250

DN 300

DN 350

DN400

DN 500

DN600

DN700

DN 800

DN900

DN 1000

DN 1200

2 3 4 5 10

10 2 3 4 5 10 2 3 4 5 10 2 3 4 5 10 2 3 4 5 10 2 3 4 5 10

-1 34

2 34 5

[ l/s ]

[ m/h]

Tab. Sensor rangesin m3/h according to their sizes

Fig. Limit ofmaximumrelativeerror ofmeasurement

Diagramfor correct sensor size selection.

S10 A25 B25 C25 C50 D25 D50 D100

Range Q3/Q1

R10 R25 R25 R25 R50 R25 R50 R100

10 10.63 1 1.6 1.6 2.5 2.5 2.5

15 2.5 1.6 2.5 4 4 6.3 6.3 6.3

20 42.5 4 6.3 6.3 10 10 10

25 6.3 4 6.3 10 10 16 16 16

32 10 6.3 10 16 16 25 25 25

40 16 10 16 25 25 40 40 40

50 25 16 25 40 40 63 63 63

65 40 25 40 63 63 100 100 100

80 63 40 63 100 100 160 160 160

100 100 63 100 160 160 250 250 250

125 160 100 160 250 250 400 400 400

150 250 160 250 400 400 630 630 630

200 400 250 400 630 630 1000 1000 1000

250 630 400 630 1000 1000 1600 1600 1600

300 1000 630 1000 1600 1600 2500 2500 2500

350 1000 630 1000 1600 1600 2500 2500 2500

400 1600 1000 1600 2500 2500 4000 4000 4000

450 1600 1000 1600 2500 2500 4000 4000 4000

500 2500 1600 2500 4000 4000 6300 6300 6300

600 2500 4000 6300 6300 10000 10000 10000

700 2500 4000 6300 6300 10000 10000 10000

800 4000 6300 10000 10000

900 4000 6300 10000 10000

1000 6300 10000

1200 6300 10000

Range marking

0.25 0.5

0.5

1.5

2.5

0.75 1

±F

10 11 12

[ % ]

v[m/s ]

DN400..1200

DN10..25,250..350

DN32..200

FLOMAG 3000 - Installation and Operation Manual

Volba výstelkysníma eBlock diagram of the flowmeter

Mainadvantageofthemag-

neticflowmeter FLOMAG3000

isitssignificant variability.Flow-

meter converter inbasicversion

consistsonlyofpowersupply,

microcomputer and sensorin-

put module(module1). Display,

outputsand other optionalfea-

turesare availableasplug-in

modules.Thus,customer pays

onlyfor featuresthathereally

uses.Plug-inmodulescontain

memorieswhere allconfigura-

tiondata isstored. In thisway,

optionalfeaturescan beadded

or modified asrequiredanytime

duringtheservicelifeofthe

flowmeter.

There are 4free positions

available(module4, 5, 6and 7)

for binaryand analog output

modules.Theirsignalsareusu-

allyprocessed byconnected

technological devices.Alloutput

moduleshavegalvanicisola-

tion.At thesametime, up to 4

binaryoutput modulescanbe

fitted. Thesecan operate either

aspulseor frequencyoutputs

for flowrateindication. Alterna-

Power

supply

module 4 B1

Binaryoutput

module V1

Display

module 1 S1

Sensor input

module2F1

Electrodecleaning

module 5 B1

Binaryoutput

module 6 C1

RS 232 interface

module 7 A3

Analog. output

Microcontroller

module 3 M1

Data logger

Sensor

85-265 VAC

(24V,12V,AC/DC)

Fig. 19: Blockdiagramofthe flowmeter

tively,theycanservefor indica-

tionofflowmeter limitcondi-

tions.Galvanicisolation is en-

sured byanoptoelementor a

relay.Oneposition(module7)

isdedicatedfor the activeana-

logoutputmodule.Modules

withvariousaccuracyand

rangesare available. One posi-

tion (module6) isdesignedfor

the serialcommunicationmod-

ule. RS 232,RS485or M-

Businterfacecan be plugged

in.

Position(module2) isforthe

electrochemicalelectrodes

cleaningmodule.

A Module1

B Sensor connection

C Connected

D internally

E for compact version

1 module2 F2-F3

3 Not connected

6 module4

7 A4, B1-B5, E1

8 module5

9 A4, B1-B5, E1

10 module6

11 A4, B1-B5, C1, D1, D2, E1

12 module7

13 A1 - A5, B1-B5,E1

15 Not connected

17 L

18 NPowersupply

19 PE

Terminal connections

T0,5A

250V

ABCDE

B1B5C1A1

Magnetic flowmeterwww.flomag.com

LOMAG3000

Display

Sensor

connection

Relay ou

250VAC/

RS 232

0(4)..20m

Analog o

85 - 2

50 - 6

Power

T0,5A / 250V

Tab. Converter terminals Fig. 20 Converter –location ofterminals

The converter isintegratedina

ruggedaluminiumbox.After

openingthe boxyou will gain

access to terminals.Terminals

17, 18and19arefor power

supply.TerminalsA,B, C, D

and Eare used for thesensor.

For compactversion,the sen-

sor isconnected internallyand

terminalsremainfree. Termi-

nals1to16are usedfor con-

nectionofinputsand outputsof

optionalmodules(binaryout-

puts,current output,RS232,

RS485 etc.)

FLOMAG 3000 - Installation and Operation Manual

For the remote sensor, there

isaterminalboxinitstapping

(see figure 21). The sensor

shouldbe connectedtothe con-

verter usingadoubleshielded

cable. You canuseour special

sensor cable PAAR-LiYCY-CY

[1X(2X0,25LiYCY)+1X(2X0,75

LiYCY)+1X0,75]CY (lengthup

to 200m)or standard double

Maximumlength ofthe cable

between evaluation unitandthe

sensor issignificantlylimited by

conductivityofmeasured fluid,

asshownin Figure23.

Remote versionshouldbeused

when measured fluidistoohot

to avoidheattransfer to con-

verter.SeeFigure24for as-

sessment ofremote version

utilization.

Parallelrunning ofpowerand

100

200

0255075 100125150175200

Maximumlengthofcable [m]

Fluid conduc tivity

[ S/cm ]

shielded cable Lapp UNI-

TRONIC CyPiDy2x2x0.25 or

Alpha1243/2C (length up to 50

m).

Fig. 21: Sensor terminalbox Fig. 22: Remote sensor connection

signalwiresishighlyinappropri-

ate; especiallyincase ofthe

cablethat connectsthesensor

withtheremote converter.If the

instrument isused inenviron-

ment withstrong electromag-

neticinterference,cables

shouldberather asshortas

possible.

For connection ofelectronic

converter input and outputter-

minals,shielded cablesare suit-

able.

For connection ofmainsvolt-

age, astandard three-core ca-

ble,e.g. CYKY3x1,5(wire) or

VM03VQ-F 3x1 (wire strand) is

recommended. The instrument

hasnoswitchso itshouldbe

fused and switched using other

device.

Fig. 23: Maximumlengthofthe cableand conduc-

tivity

Fig. 24: Selection ofversion according to temperature

A B C D E

Yellow/Green

Yellow

Red

White

Brown

Green

B1B1C1A3

Magneticflowmwter www.flomag.com

LOMAG3000

Display

Sensor

input

RS 232

4..20mA

Analog. output

85 - 265 V

48 - 63 Hz

AABBCCDDEE

Sensor Sensor

ABCDEABCDE

Cable

PAAR-LiYCY-CY

[1X(2X0,25LiYCY)

+1X(2X0,75 LiYCY)

+1X0,75]CY

Cable

Lapp UNITRONIC

Cy PiDy 2x2x0.25

Alpha 1243/2C

-20

-10

-60-40-20 0204080

100

120

140

160

Fluid temperature[ °C]

[

]

TG,MG

NG T

Remote version

Heating

Remote or

compact

version

FLOMAG 3000 - Installation and Operation Manual

Displayed data

Fig. 25: Displayeddata

The instrument isequippedwith

ahigh qualitybacklittwo-line

alphanumerical displaywith

character height 9.6mm (2x16

characters)providinggood

readabilityevenfromlonger

distances.Backlight function

worksinenergysavingmode.

Backlighttimeislimited to 254

secondsafter lastpressingof

anykey.Ifbacklight isoff,

pressing ofanykeywillswitchit

on again. Backlight timecan be

set inmenu from20 secondsto

254 seconds.Setting to0

switchesbacklightpermanently

off;setting to255switchesit

permanentlyon.

Up to8basicreadingscanbe

read fromthe converter display.

You can alternatethemusing

1key.Additionalinformation

accessiblevia 2keyisavail-

able for some displayeddata.

Flow rate

-Flowrate value treatedby

floatingaveraging. Number of

averagingstepscanbe

changedinrange from1to 256.

Flowrateunitscanbechanged

asrequired.

Number ofdisplayed decimal

places canbesetinrangefrom

0 to 4.

Total volume (+)

-Totalvolumeofliquidflowed

indirectionofarrowonthe sen-

sor fromstart ofmeasurement.

Total volume (-)

-Totalvolumeofliquidflowed

inoppositedirection of arrowon

the sensor fromstart ofmeas-

urement.

Volume difference

-Differencebetweenpositive

and negativevolumesflowed

fromstart ofmeasurement.

Operation time

-Totaltimeofoperationfrom

initialswitching instrument on in

hoursand minutes.

Percent. flow rate

-Flowrate information indicated

byhorizontalbar (itswidthcor-

respondsto flowrate) andas

numericvalue inper centsof

chosen maximumvalue.

Last error

-Abbreviatedtextofthelast

error message.

Current flow rate

-Flowrate valueuntreatedby

floating averaging.

Temporary volume +

-User resettablevalue ofvol-

umeflowedindirectionofarrow

on the sensor.

Temporary volume -

-User resettablevalue ofvol-

umeflowed inoppositedirec-

tionofarrowonthesensor.

Temporary difference

-User resettablevalue ofdiffer-

encebetween volumesflowed

indirectionandinoppositedi-

rection ofarrowon the sensor.

Temporary time

-User resettablevalue ofvol-

umeflowedindirectionofarrow

on the sensor.

Valuesoftemporarycounters

can be reset byholding 3key

andsimultaneouspressing 4

key.Thiswillreset allcounters

at the sametime–both vol-

umesand time.

Batching

-Showsinformation aboutthe

running batch. Detailedinforma-

tionisgiven inchapter Batch-

ing.

FLOMAG 3000 - Installation and Operation Manual

Archiving

Electromagneticflowmeter

FLOMAG3000 automatically

savesinfixed timeintervals,

the value oftheflowedvolume.

There are threearchives.

Hour archivewhere itispossi-

bleto findtheflowedvolumes

aboutthe last192hours(8

days).

Dailyarchivewhere itispos-

sibleto findtheflowedvolumes

aboutthelast192 days(more

than half year).

Montharchivewhere itispos-

sibleto findtheflowedvolumes

about the last 12 months.

Upper lineshowsalwaystime

intervalofthe iteminthear-

chive. Second lineshowsthe

flowed volumeinthe fixedtime

intervalandthepowerofftime

inthe fixedtimeinterval(the

flowmeter waswithout power

supply).

Listing in archive

Pushing key 1,rollto item

Totalvolume+.Byrepeated

pushing ofkey 2youcanfind

graduallyFlowrate+,hourar-

chive, dayarchiveandmonth

archive.

Byrepeated pushing ofkey

3,inthehour archiveyoucan

see graduallythesaved sam-

plesfromthe previoushour,

totally192 hoursback.

Byrepeated pushing ofkey

3,inthedailyarchiveyoucan

see graduallythesaved sam-

plesfromthe previousday,to-

tally192daysback.

Byrepeated pushing ofkey

3,inthe month archive you

can see graduallythe saved

samplesfromthe previous

month, totally12monthsback.

Ifyou wanttogobackto the

lastsavedsample, please push

andholdkey3andtogether

with itpush key 4.

Fig. Hour archive

Fig. Dailyarchive

Fig. Month archive

Fig. Legend

Fig. Hour archive moving

Fig. Dailyarchive moving

Fig. Month archive moving

Ok- without power off

-#s- power off timein secunds

-#m- power off timein minutes

-#h- power off timein hours

-#d- power off timein days

Error messages

Fig. Error messages

In case of afault, an error

message with short de-

scription of the fault is

shownimmediatelyat the

LCD.

The error message begins

with character Efollowed

by error'snumber.If the

errorisconnectedwitha

defect of amodulethan it is

followed also bycharacter

Mand the number of the

module. Afterpushing but-

ton 1theflowmeter re-

turns to value displaymode

and at thesame timetheer-

ror messageissavedto last

errorregister. During the indi-

cation of the error message,

the flowmeter is measuring.

In caseof error E-7, E-8 and E

-13, theflowmeter indicates 0

if the mentionederrormes-

sage isnot forbidden inthe

menu.

Errormessages are listed

belowtogether with recom-

mendation howto repair.

E0: No error

E1: EEPROMChecksum

error

Checksum error saved in

the module-re-check data

inthemoduleandsave

again

E2: Stack overflow

For module„B“ inpulse

mode-thetimeconstants

are toolong, the flowrate is

higher than itispossibleto

send pulses,stack overflow

of un-sentpulses-change

pulse lengthandspace

length or volume for 1 pulse

E3: Frequencylimit ex-

ceeded

For module„B“ infre-

quency mode, itisrequired

higher output frequency than

the moduleisabletosend,

flow rateishigher thanit

wasassumed -set higher

flow rate valuefor 1kHz.

E4: Power fail

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