Flomag 3000 Installation And Operation Manual

FLOMAG s.r.o.

V Aleji 180/20a
CZ-620 00 Brno
Czech Republic
tel: [phone]
fax: [phone]
e-mail: [e-mail]

www.flomag.com

Magnetic Flowmeter

FLOMAG

®

3000

Installation and Operation

FLOMAG 3000 -

Installation and Operation Manual

2

FLOMAG 3000 -

Installation and Operation Manual

3

An magnetic flowmeter is used
for volume flow measurement of
electrically conductive liquids.
Measurement principle is based
on Faraday law on electromag­netic induction. A sensor con­sists of a non-magnetic tube
with non-conductive lining,
measuring electrodes and two
coils generating electromag­netic field. Flowing liquid forms
a conductor. Magnetic field in­duces voltage U in this conduc­tor that is proportional to mag­netic induction B, distance be­tween electrodes d and flow
velocity v.

U = B x d x v

As magnetic induction and dis­tance between electrodes are
constant, induced voltage is
proportional to velocity of liquid
flow in the tube. Volume flow
rate is product of flow velocity
and tube cross section.

Q = v x S

Fig.1 - Principle of measurement

Principle of measurement

Technical solution

The magnetic flowmeter itself
consists of two basic parts – a
flow sensor and a converter.
The converter can be either an
integral part of the sensor
(compact version) or separated,
connected with the sensor us­ing a cable (remote version).
The sensor consists of a non­magnetic tube with non­conductive lining, measuring
electrodes, excitation coils and
cables. There are various sen­sor versions available enabling
connection to adjacent tubes
with flanges (type P) and fittings
(gas fitting type G or food indus­try fitting type V) or wafer which
are installed between flanges
using clamps (type B). Non­conductive lining can be made
of technical rubber (types TG,
MG or NG) or Teflon (type T).
The converter is used for gener­ating excitation current in coils,
processing of signal from meas­uring electrodes, displaying of
measured data and generating
output signals. Current in exci­tation coils has constant value
250 mA or 125 mA and is pulse

generated with alternating po­larity to avoid permanent mag­netization of the sensor. Excita­tion pulse frequency can be
chosen from six values – 25 Hz,
12,5 Hz, 8,33 Hz, 6,25 Hz,
3,125 Hz and 1,56 Hz. Excita­tion current of 250 mA with ex­citation frequency 3,125 Hz is
suitable for all standard applica­tions. Other settings can be
used for specific applications.
Excitation current and fre­quency are factory set before
sensor calibration and their later
modifications are not allowed.

Voltage induced in measuring
electrodes is measured always
on the end of excitation pulse
when magnetic field is steady.
Each excitation pulse is fol­lowed by refreshing period. Sig­nal processing and parameter
setting are performed digitally
and the converter contains no
setting controls or other moving
parts what ensures its high reli­ability and long-term stability.

T

t

I

+I

-I

m

m

1/8T 3/8T

1/8T

0

Fig. 2 - Excitation pulse form

FLOMAG 3000 -

Installation and Operation Manual

4

min 5 x DN min 3 x DN

The flowmeter will give the best
results when flow of liquid is
steady. Therefore a few basic
recommendations should be
observed for its locating in a
pipeline. There should be no
transitions between the sensor
and the adjacent pipeline that
could be a source of turbulence.
Correct axial alignment should
be observed during installation.
A gasket should not exceed
internal edges of tubes.

If more interfering elements are
present near the sensor (e.g.
bends, fittings), required steady
length should be multiplied by
number of these interfering ele­ments.
Reductions with slopes up to 8°
can be included in steady
lengths.

x

x

Minimum straight steady
lengths of pipeline are required
on both sides of the flow sen­sor. Their lengths have to be
proportional to pipeline internal
diameter.

Fig. 3 - Overlaps

Fig.4 - Steady lengths

8

°

m

a

x

m

a

x

4

5

°

min 2 x DN

Fig.5 - Reduction

If water in the pipeline is
pumped by a water pump, the
sensor should be always lo­cated behind the pump to avoid
low pressure that can damage
the sensor. Steady length of at

least 25DN is required between
the pump and the sensor.

Fig. 6 - A water pump

For the same reason, never
locate stop valves behind the
sensor.

Fig. 7 - Stop valves

The sensor can work both in
horizontal and vertical positions;
only axis of measuring elec­trodes inside the sensor must
always remain in horizontal po­sition and tapping of the sensor
should be directed upwards at
horizontal installations.

Fig. 8 - Electrode axis

For vertical installations, liquid
should flow upwards.

Fig. 9 - Vertical installation

To ensure correct measurement
and to avoid air lock, whole
sensor cross section should be
flooded. Therefore never locate
the sensor in upper parts of the
pipeline or in vertical positions
with liquid flowing downwards.

Fig.10 - Danger of air lock

If permanent flooding of whole
pipeline cross section cannot be
ensured, it is possible to locate
the sensor in a low water trap
so that it can be always com­pletely flooded. Free water dis­charge should be located 2DN
higher than the sensor.

Fig.11 - Permanent flooding

To avoid vibrations that could
damage the sensor, ensure that
the adjacent pipeline is always
supported as near to the sensor
as possible.

Fig.12 - Danger of vibrations

Where continuous flow of fluid
is required and removal of the
sensor is impossible, a bypass
should be installed. The same
applies for locations where sen­sor removal would require
draining of too long part of the
pipeline.

Fig. 13 - A bypass

Installation instructions

FLOMAG 3000 -

Installation and Operation Manual

5

Correct function of the magnetic
flowmeter requires perfect elec­trical connection between the
sensor and the adjacent pipe­line, grounding potential and the
power supply protective wire.
For the flanged sensor with the
adjacent conducting pipeline,
flanges should be electrically
connected and the pipeline
grounded.

If the adjacent pipeline is
non-conductive, grounding rings
should be inserted in it or
equivalent method should be

Fig.16: Grounding rings

Fig.17. The wafer sensor

Fig.18: Cathodic protection

Fig.15: Grounding of flanges

connection of sensor clamping
flanges with grounding point of
the sensor.

If electric current flows through
the pipeline, e.g. for pipeline
cathodic protection against cor­rosion, the sensor should be
electrically isolated from the
adjacent pipeline. The sensor
should be bridged over using a
wire and galvanic isolation of
the flowmeter power supply
should be provided so that the
flowmeter can be isolated from
all other devices.

Sensor grounding

Selection of suitable sensor lining and electrode material

Linings

Sensors have a non-conductive
lining from various materials.
Choice of material depends on
measured fluid characteristics.

· Technical rubber

Technical rubber is suitable for
low aggressive fluids with op­erational temperatures from 0.1
°C to 70 °C. It fits for most wa­ter management and sewage
treatment applications. It is
manufactured in two variants

“TG” – with hard structure and
“MG” – with soft structure. Soft

structure is used for fluids with
higher content of abrasive parti­cles (e.g. sand). It is not suit­able for drinking water.

· Resistant rubber

Type “NG” is suitable for me­dium aggressive fluids with op­erational temperatures from 0.1
°C to 90 °C. It can be used for
measurement of hot service
water, condensate etc., as well
as for drinking water. If tem-

perature 100 °C can be ex­ceeded, Teflon (PTFE) lining is
recommended.

· Teflone or Hallar

Type “T” is the most universal
lining for aggressive fluids with
operational temperatures from ­20 °C to 150 °C. It is suitable for
chemical and food industry ap­plications.

Electrodes

Choice of material of measuring
electrodes also depends on
measured fluid characteristics.

· Stainless steel – “Ss”

Standard electrodes are made
of stainless steel AISI 316Ti.
They are suitable for all usual
water based fluids and for lower
concentrations of acids and
caustics.

· Hastelloy C-22 – “Ha”

For some special applications,
material of higher quality should
be used. Hastelloy C-276 elec-

trodes are characterized by in­creased resistance against ac­ids and caustics and usually are
suitable for most of industrial
applications.

· Titanium - „Ti“

Suitable for some acids,
lyes, chlorine, urea and sew­age.

· Platinum – “Pt”

For particularly aggressive flu­ids like concentrated acids and
caustics, chemically extremely
resistant material should be
chosen – platinum. However,
high cost of this material is its
essential drawback.

* Note – We can recommend
suitable lining and electrode
materials for your particular ap­plication.

used to connect measured fluid
electrical potential with ground.

For the wafer sensor, grounding
can be provided by electrical

FLOMAG 3000 -

Installation and Operation Manual

6

Converter is capable to detect
flow rates as low as 0.1 m/s.
Upper limit is determined by
capability of liquid to maintain
continuous flow at higher veloci­ties. This is usually true for flow
rates up to 12 m/s.

Measurement error rapidly
increases for too low flow rates,
as can be seen in the diagram.
It shows limits of maximum rela­tive measurement error as func­tion of liquid flow rate.

On the other side, too high
flow rate causes discontinuity of
flow and results in chaotic tur­bulence and vacuum traps. This
results in instable measurement
and too high drift of flow rate
values.

Ideal operational range of the
sensor is in range from 0.5 to 5
m/s. This range is highlighted in
the diagram for correct size se­lection.

Flow rate ranges for individual
sizes are chosen to meet EN

14154 standard and they are
shown in table. Preferred
ranges are highlighted in bold.
For non-specified working me­ters, other range can be also
specified on request.

If range is not specified in a
purchase order, the sensor will
be calibrated in preferred range
in accordance with the table
above.

Correct sensor size selection

10

1

0.1

Flow velocity [ m/s ]

Volume flow 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

0

2

3

DN 10

D

N 20

DN 25

D

N 32DN

4

0

D

N 50DN 65DN 80

D

N

100

DN 125

D

N

1

50

D

N 15

D

N

20

0

D

N

25

0

DN 300

D

N 350DN

400

DN 500

D

N

600

D

N

700

D

N 800DN

900

D

N 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

3

4

2 34 5

3

2

Tab. Sensor ranges in m3/h according to their sizes

Fig. Limit of maximum relative error of measurement

Diagram for correct sensor size selection.

DN

S10 A25 B25 C25 C50 D25 D50 D100

Range Q3/Q1

R10 R25 R25 R25 R50 R25 R50 R100

10

1 0.63

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

4 2.5

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

1.5

2

2.5

3

0.75 1

±F

10 11 12

[ % ]

v [ m/s ]

9

DN400..1200
DN10..25, 250..350
DN32..200

FLOMAG 3000 -

Installation and Operation Manual

7

Volba výstelky snímače Block diagram of the flowmeter

Main advantage of the mag­netic flowmeter FLOMAG3000
is its significant variability. Flow­meter converter in basic version
consists only of power supply,
microcomputer and sensor in­put module (module 1). Display,
outputs and other optional fea­tures are available as plug-in
modules. Thus, customer pays
only for features that he really
uses. Plug-in modules contain
memories where all configura­tion data is stored. In this way,
optional features can be added
or modified as required anytime
during the service life of the
flowmeter.

There are 4 free positions
available (module 4, 5, 6 and 7)
for binary and analog output
modules. Their signals are usu­ally processed by connected
technological devices. All output
modules have galvanic isola­tion. At the same time, up to 4
binary output modules can be
fitted. These can operate either
as pulse or frequency outputs
for flow rate indication. Alterna-

Power
supply

module 4 B1
Binary output

module V1
Display

module 1 S1
Sensor input

module 2 F1
Electrode cleaning

module 5 B1
Binary output

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: Block diagram of the flowmeter

tively, they can serve for indica­tion of flowmeter limit condi­tions. Galvanic isolation is en­sured by an optoelement or a
relay. One position (module 7)
is dedicated for the active ana­log output module. Modules
with various accuracy and
ranges are available. One posi­tion (module 6) is designed for

the serial communication mod­ule. RS 232, RS 485 or M­Bus interface can be plugged
in.

Position (module 2) is for the
electrochemical electrodes
cleaning module.

A

Module 1

B

Sensor connection

C

Connected

D

internally

E

for compact version

1

module 2 F2 - F3

2
3

Not connected

4
5
6

module 4

7

A4, B1-B5, E1

8

module 5

9

A4, B1-B5, E1

10

module 6

11

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

12

module 7

13

A1 - A5, B1-B5, E1

14
15

Not connected

16
17

L

18

N

Power supply

19

PE

Terminal connections

T0,5A
250V

ABCDE

12345678910111213141516PELN

B1B5C1A1

+

-

S1
V1

--

Magnetic flowmeter www.flomag.com

FLOMAG3000

Display

Sensor
connection

Relay ou

tpu

t

250VAC/

1

A

RS 232

0(4)..20mAAnalog o

utput

85 - 2

40

V

50 - 6

0 H

z

Power

T0,5A / 250V

Tab. Converter terminals Fig. 20 Converter – location of terminals

The converter is integrated in a
rugged aluminium box. After
opening the box you will gain
access to terminals. Terminals
17, 18 and 19 are for power

supply. Terminals A, B, C, D
and E are used for the sensor.
For compact version, the sen­sor is connected internally and
terminals remain free. Termi-

nals 1 to 16 are used for con­nection of inputs and outputs of
optional modules (binary out­puts, current output, RS232,
RS485 etc.)

FLOMAG 3000 -

Installation and Operation Manual

8

For the remote sensor, there
is a terminal box in its tapping
(see figure 21). The sensor
should be connected to the con­verter using a double shielded

cable. You can use our special
sensor cable PAAR-LiYCY-CY

[1X(2X0,25 LiYCY)+1X(2X0,75
LiYCY)+1X0,75]CY (length up

to 200 m) or standard double

Maximum length of the cable
between evaluation unit and the
sensor is significantly limited by
conductivity of measured fluid,
as shown in Figure 23.
Remote version should be used
when measured fluid is too hot
to avoid heat transfer to con­verter. See Figure 24 for as­sessment of remote version
utilization.
Parallel running of power and

0

25

50

100

200

0255075

100125150175200

Maximum length of cable

[ m ]

Fluid conductivity

[ S/cm ]

m

shielded cable Lapp UNI­TRONIC Cy PiDy 2x2x0.25 or
Alpha 1243/2C (length up to 50

m).

Fig. 21: Sensor terminal box Fig. 22: Remote sensor connection

signal wires is highly inappropri­ate; especially in case of the
cable that connects the sensor
with the remote converter. If the
instrument is used in environ­ment with strong electromag­netic interference, cables
should be rather as short as
possible.
For connection of electronic
converter input and output ter­minals, shielded cables are suit-

able.
For connection of mains volt­age, a standard three-core ca­ble, e.g. CYKY 3x1,5 (wire) or
VM03VQ-F 3x1 (wire strand) is
recommended. The instrument
has no switch so it should be
fused and switched using other
device.

Fig. 23: Maximum length of the cable and conduc-

tivity

Fig. 24: Selection of version according to temperature

A B C D E

Yellow/Green

Yellow

Red

White

Brown

Green

AB

CDE12345678910111213141516PEL

N

B1B1C1A3

+

-

S1
V1

Magnetic flowmwter www.flomag.com

FLOMAG3000

Display

Sensor
input

RS 232

4..20mA

Analog. output

85 - 265 V

48 - 63 Hz

T0,5A / 250

V

AABBCCDDEE

PE

N
L

M1F

1

17181

9

AABBCCDDEE

Sensor

Sensor

ABCDEABCDE

Cable

PAAR-LiYCY-CY
[1X(2X0,25 LiYCY)
+1X(2X0,75 LiYCY)
+1X0,75]CY

Cable

Lapp UNITRONIC
Cy PiDy 2x2x0.25
or
Alpha 1243/2C

-20

-10

0

10

20

30

40

50

60

-60-40-20

0204080

100

120

140

160

Fluid temperature [ °C ]

Ambient temperature [ °C

]

TG, MG

NG

T

Remote version

Heating

Remote or
compact
version

FLOMAG 3000 -

Installation and Operation Manual

9

Displayed data

Fig. 25: Displayed data

The instrument is equipped with
a high quality backlit two-line
alphanumerical display with
character height 9.6 mm (2x16
characters) providing good
readability even from longer
distances. Backlight function
works in energy saving mode.
Backlight time is limited to 254
seconds after last pressing of
any key. If backlight is off,
pressing of any key will switch it
on again. Backlight time can be
set in menu from 20 seconds to
254 seconds. Setting to 0
switches backlight permanently
off; setting to 255 switches it
permanently on.

Up to 8 basic readings can be
read from the converter display.
You can alternate them using

1 key. Additional information
accessible via 2 key is avail-

able for some displayed data.

Flow rate

- Flow rate value treated by
floating averaging. Number of
averaging steps can be
changed in range from 1 to 256.
Flow rate units can be changed
as required.

Number of displayed decimal
places can be set in range from
0 to 4.

Total volume (+)

- Total volume of liquid flowed
in direction of arrow on the sen­sor from start of measurement.

Total volume (-)

- Total volume of liquid flowed
in opposite direction of arrow on
the sensor from start of meas­urement.

Volume difference

- Difference between positive
and negative volumes flowed
from start of measurement.

Operation time

- Total time of operation from
initial switching instrument on in
hours and minutes.

Percent. flow rate

- Flow rate information indicated
by horizontal bar (its width cor­responds to flow rate) and as
numeric value in per cents of
chosen maximum value.

Last error

- Abbreviated text of the last
error message.

Current flow rate

- Flow rate value untreated by
floating averaging.

Temporary volume +

- User resettable value of vol­ume flowed in direction of arrow
on the sensor.

Temporary volume -

- User resettable value of vol­ume flowed in opposite direc­tion of arrow on the sensor.

Temporary difference

- User resettable value of differ­ence between volumes flowed

in direction and in opposite di­rection of arrow on the sensor.

Temporary time

- User resettable value of vol­ume flowed in direction of arrow
on the sensor.
Values of temporary counters

can be reset by holding 3 key
and simultaneous pressing 4

key. This will reset all counters
at the same time – both vol­umes and time.

Batching

- Shows information about the
running batch. Detailed informa­tion is given in chapter Batch­ing.