Xylem Magflux User Manual

Electromagnetic Flow Meter

Electromagnetic Flow Meter

Installation and User Manual

1EN 3.05 MagFlux Manual 1212

FW: 842018/842009

Electromagnetic Flow Meter

Declaration of Conformity

Konformitetserklæring

Vi, MJK Automation A/S,
DK-2850 Nærum, påtager os
det fulde ansvar for at produktet

Declaration of Conformity

We, MJK Automation A/S,
DK-2850 Nærum, declare under
our sole responsibility that the
product

Electromagnetic Flowmeter

som denne erklæring angår,
er i overensstemmelse med
følgende standard(er) eller andre
normdokument(er).

EN61000-6-3/-4:2001,
EN61000-6-1/-2:1999

efter bestemmelserne i
direktiv

89/336/EEC; 92/31/EEC

Declaration de conformite

Nous, MJK Automation A/S,
DK-2850 Nærum, déclarons
sous notre seule responsabilité
que le produit

to which this declaration relates
is in conformity with the following
standard(s) or other normative
document(s).

EN61000-6-3/-4:2001,
EN61000-6-1/-2:1999

following the provisions of
Directive

89/336/EEC; 92/31/EEC

Dichiarazione di conformità

Noi, MJK Automation A/S,
DK-2850 Nærum, dichiariamo
sotto la nostra esclusiva respon­sabilità che l’apparecchio

Konformitätserklärung

Wir, MJK Automation A/S,
DK-2850 Nærum, erklären in
alleiniger Verantwortung, dass
das Produkt

auf das sich diese Erklärung
bezieht mit der/den folgenden
Nor me(en) oder normativen
Dokument(en) übereinstimmt.

EN61000-6-3/-4:2001,
EN61000-6-1/-2:1999

Gemäss den Bestimmungen der
Richtlinie

89/336/EEC; 92/31/EEC

Declaración de Conformidad

Nosotros, MJK Automation A/S,
DK-2850 Nærum, declaramos
bajo nuestra única responsabili­dad que el producto

Electromagnetic Flowmeter

auquel se réfère cette déclara­tion est conforme á la (aux)
norme(s) ou autre(s) document(s)
normatif(s)

EN61000-6-3/-4:2001,
EN61000-6-1/-2:1999

conformément aux dispositions
de Directive

89/336/EEC; 92/31/EEC

al quale questa dichiarazione si
riferisce, è conforme alla seg­uente normativa(e) standard o ad
altri documenti di normativa(e)

EN61000-6-3/-4:2001,
EN61000-6-1/-2:1999

conformemente alla disposizioni
della Direzione

89/336/EEC; 92/31/EEC

21.11.2006

Jens Kruse

2EN 3.05 MagFlux Manual 1212

al cual se refiere esta de­claración, está en conformidad
con la(s) siguente(e) norma(s) u
otros documentos normativos

EN61000-6-3/-4:2001,
EN61000-6-1/-2:1999

según las disposiciones de la(s)
directiva(s)

89/336/EEC; 92/31/EEC

Electromagnetic Flow Meter

Table of Contents

1. Introduction 7

About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Operating Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

The MagFlux

®

Flow Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2. Safety, Repair and Product Identification 13

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Physical Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Product Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3. Flow Sensor 15

Minimum conductivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Liner selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Electrode selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Mounting location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Pressure loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Sizing Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Pipe System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Cabinet Mounted on the Flow Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Potential Equalization and Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Type 7100/7200/7600 in Conductive Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Type 7100/7200/7600 in Non-conductive Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Type 7300/7400 in Conductive Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Type 7300/7400 in Non-conductive Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

4. Flow Converter 25

Electrical Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Changing the Power Supply Voltage 230/115 V AC . . . . . . . . . . . . . . . . . . . . . . . . .27

Analogue Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Digital Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Local (compact) Flow Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Remote Flow Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Converter Connection Board - Local . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Converter Connection Board - Remote . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

5. System Configuration Examples 33

Compact Converter and Display Unit on Flow Sensor. . . . . . . . . . . . . . . . . . . . . . . .33

Remote Converter with Connection Box on Flow Sensor . . . . . . . . . . . . . . . . . . . . . .34

Wiring Schematic #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

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Electromagnetic Flow Meter

Remote Display and Multiple Converters Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Wiring Schematic #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

6. Startup 39

Initial Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Initial Flow Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Flow Direction Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Language Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Display Read-out, one connected unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Display Read-out, several connected units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Display Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Initial Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

7. MagFlux Menus 47

Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Specify Main Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Factory Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Data Logger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Graph Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Set Sensor Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Converter Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Minimum Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

Averaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

mA Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Flow Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

Flow Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Forward & Rev. (12mA=0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Forward & rev. (4mA=0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

Not in use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

Totalizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Settings and Limits for Resettable Totalizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Resettable Totalizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Resettable Forward Totalizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Resettable Reverse Totalizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Resettable Sum Totalizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

Non-Resettable Totalizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

NR Forward Totalizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

NR Reverse Totalizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

NR Sum Totalizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Batch Counters 1 & 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

Settings and Limits for Batch Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

High Flow/Low Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Flow Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83

Empty Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

4EN 3.05 MagFlux Manual 1212

Electromagnetic Flow Meter

24h Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

Service Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86

Display Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Set Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

Modbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Factory Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

Display SW Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

8. Mechanical Dimensions 101

Standard Flanges - EN-1092-1:2001 - Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Standard Flanges - ANSI B 16.5 - U.S.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102

Standard Flanges - AS-4087-2004 - Australia . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Standard Flanges - AS-4087-2004 (cont'd) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Standard Flanges - AS-4087-2004 (cont'd) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Appendix A. Pop-up and Error Messages 107

Appendix B. MJK-Field Link Software 111

Appendix C. FAQs - Frequently Asked Questions 115

Appendix D. Front Panel Cut-out Drawing 118

Appendix E. Test Certificate 119

Appendix F. Log Files 120

Appendix G. Digital Input/Output Connections 123

Appendix H. Remote Slave Display Unit 124

Connection Board - with a remote "slave" display unit . . . . . . . . . . . . . . . . . . . . . .124

Converter Connection Board - with a "master" display unit . . . . . . . . . . . . . . . . . . . 125

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Configuration for the master unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125

Configuration for the slave unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125

Main Menu Overview 126

Converter Setup Menu Overview 128

Service Menu Overview 138

Display Setup Menu Overview 142

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Electromagnetic Flow Meter

6EN 3.05 MagFlux Manual 1212

Electromagnetic Flow Meter

1. Introduction

Thank you for choosing the MJK MagFlux® electromagnetic flow meter.
We have done our utmost to design and manufacture a flow meter that
satisfies your requirements.

The MagFlux® is suitable for flow measurement in all kinds of conduc­tive fluids, and it is especially suited for flow measurement of water, waste
water, sludge and other fluids containing particles.

The flow meter is easy to install and put into service. However, read this
manual first to learn about the MagFlux® electromagnetic flow meter and
all its features.

You can always contact your local representative or the MJK hot lines for
advice and guidance:

• Europe Tel.: [phone] E-mail: [e-mail]

• Denmark Tel.: [phone] E-mail: [e-mail]

• Norway Tel.: [phone] E-mail: [e-mail]

• Sweden Tel.: [phone] E-mail: [e-mail]

• Holland Tel.: [phone] E-mail: [e-mail]

• USA Tel.: [phone] E-mail: [e-mail]

• Australia Tel.: [phone] E-mail: [e-mail]

Visit our web sites at www.magflux.dk and www.mjk.com to learn more
about MJK Automation, our other products and the people behind them.

MagFlux

®

is a registered trademark of MJK Automation A/S, Denmark.

Trademarks & acknowledgements

Mµ Connect, Connect, MagFlux, Chatter, SuSix, Oxix, pHix and Shuttle
are ® registered trademarks of MJK Automation A/S, Denmark.

Expert and Instrument Link are ™ trademarks of MJK Automation A/S,
Denmark.

VLT® is a registered trademark of Danfoss A/S.
All other trademarks are the property of their respective owners.

MJK Automation A/S is a Xylem Brand.

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Electromagnetic Flow Meter

About this Manual

The manual is divided into a table of contents, eight chapters, seven ap­pendices and an index.

1. Introduction

Contains a presentation of the MJK MagFlux

meter, the structure of this manual and the operating principles.

2. Safety, Repair and Product Identification

Provide answers to issues regarding safety, mounting, repair,

restrictions and product identification.

3. Flow Sensor

Describes the physical specifications and installation guidelines for the

flow sensor such as liner and electrode selection, example pipe
systems, sizing chart, etc.

4. Flow Converter

Describes the physical specifications and installation rules for the flow

converter such as power supply, in- and outputs, sensor/converter/
display configurations, etc.

5. System Configuration Examples

Illustrates how MagFlux

®

sensors, converters and display units can be

interconnected in real-life scenarios.

®

electromagnetic flow

6. Startup

Describes important checks and basic settings to get started including

the display and keyboard user interface.

7. MagFlux Menus

Contains a comprehensive description of the MagFlux

®

menus,

options and utilities.

8. Mechanical Dimensions

Lists the flange and sensor dimensions and specifications.

* * * * *

8EN 3.05 MagFlux Manual 1212

Electromagnetic Flow Meter

Appendix A. Pop-up Events / Error Messages

Lists possible pop-up messages, explains their meaning and offer

solutions to error conditions.

Appendix B. MJK-Field Link Software Upgrade

Describes in detail how to utilise the unique and intuitive MJK-Field Link

software program to upload new display and converter firmware
versions.

Appendix C. FAQs - Frequently Asked Questions

Contains answers to questions that are often asked.

Appendix D. Front Panel Cut-out Drawing

A 1:1 scale drawing of the front panel outline and cut-out area for

installation and mounting purposes.

Appendix E. Test Certificate

Shows an example test certificate which is part of MagFlux

shipments.

Appendix F. Log Files

An example log file illustrates the format and explains the entries.

Appendix G. Digital Input/Output Connections

Illustrates how the digital in- and outputs can be interconnected.

®

* * * * *

Main Menu Overview

Is a continuous presentation of the main menu structure. The size of

this manual does not provide sufficient space for showing the complete
menu structure in one image.

Converter Setup Menu Overview

Is a continuous presentation of the converter setup menu structure.

Service Menu Overview

Is a continuous presentation of the service menu structure.

Display Setup Menu Overview

Is a continuous presentation of the display setup menu structure.

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Electromagnetic Flow Meter

Operating Principles

The electromagnetic flow meter is an instrument for measuring the flow
of conductive fluid using Faraday's electromagnetic induction law, and
consequently the fluid must be electrically conductive.

As illustrated below a magnetic field with density B - perpendicular to the
direction of flow - stretches across a fluid flowing within an electrically
isolated pipe.

The magnetic flux will induce a voltage difference (E) that can be measured
between two electrodes arranged perpendicular to the direction of flow
and the magnetic field. The voltage is proportional to the velocity (V) of the
fluid.

➀ E = B x D x V x k [Volt] where
E is the voltage that is induced between the two electrodes
B is the magnetic flux density
D is the distance between the two electrodes
V is the fluid velocity
k is a dimensionless constant
The flow of the fluid Q (m3/s) is given by the following formula:

➁ Q = π x D2 x V / 4 => V = 4 / (π x D2) where

π : is the constant pi (= 22/7)
D: is the internal diameter
V: is the fluid velocity
The combination of above formulas ➀ and ➁ gives the following formula:

E = K x B x D x Q x 4 / (π x D x D) = 4 K x B x Q / (π x D)

Evidently the voltage E is proportional to the actual flow.

10EN 3.05 MagFlux Manual 1212

Electromagnetic Flow Meter

The MagFlux® Flow Meter

Measurement

Electromagnetic flow meters may have either direct current (DC) or alter­nating current (AC) excitation.

When systems are AC excited, electrostatic and/or electromagnetic noise
may influence the measurements. A DC excited system however, is less
sensitive to noise produced by electromagnetic induction, simply be­cause the voltage induced over the electrodes will be a DC voltage. The
drawbacks are measurement errors due to electro-chemical polarization
between the electrodes and the fluid.

The MagFlux® electromagnetic flow meters are excited by a 2.5 Hz
square wave and thereby eliminate the drawbacks of both DC and AC
systems.

A microprocessor receives and measures the amplitude of the pulse with a
16-bit resolution, and converts and displays the result on the display unit.

Electrode Cleaning

Electrode cleaning is always in service to maintain clean and accurate
electrodes. The operating principle is a 55 Hz AC voltage superimposed
on the normal 2.5 Hz square wave. This step effectively reduces the risk
of a dirt layer build-up on the electrodes that eventually will deteriorate and
finally isolate electrical contact to the flow media.

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12EN 3.05 MagFlux Manual 1212

Electromagnetic Flow Meter

2. Safety, Repair and Product Identification

Safety instructions

1. Read this manual carefully.

2. Pay attention to the environment on the installation site.

3. Wear necessary protective equipment and follow all current safety
regulations.

4. The MagFlux
Always ensure that connected machinery and other equipment are
effectively put out of service (that is to remove the main fuses and lock
main and security switches in off-position) before commencing configu­ration, fault finding, servicing, maintenance work, etc.

5. WARNING: There is a risk of lethal, electrical shock from "Mains sup­ply" terminals N and L. Be careful not to touch these terminals while
the MagFlux

Physical Mounting

The MagFlux® flow converter/flow meter must not be mounted in
explosion hazardous areas!

Repair

Repair must only be made by MJK or by a service representative ap­proved by MJK.

®

can invoke a start signal for dangerous machinery.

®

is being serviced.

13

FW: 842018/842009

Electromagnetic Flow Meter

Product Identification

A delivery will usually consist of a MagFlux® converter and a MagFlux®
flow sensor. Check that the item(s) delivered corresponds to the ordered
item(s). The part number and the calibration code are printed on an iden­tification label sticked onto the flow converter shipping box and on a label
on the flow converter itself. The part number, the serial number, the cali­bration code and the electrode/lining data for the flow sensor are printed
on a green name plate (see example below).

This calibration code (Cal. code) is unique and provides the MagFlux®
converter with information about flow sensor number, nominal diameter of
the flow sensor and calibration data for the flow sensor.

The current converter firmware requires an 8-character input, but it also
accepts 6 characters plus two "Ok"s. The example above (dw5uq4) would
require that you enter: d w 5 u q 4 "Ok" "Ok", where "Ok" indicates that
you press the "Ok" key without selecting any character. Only small letters
can be entered from the MagFlux® keypad.

If changes are needed to the unique sensor calibration code following
initial setup, this is the calibration code that the "Sensor Calibration Code"
menu must contain (see pages 44 and 86).

14EN 3.05 MagFlux Manual 1212

Electromagnetic Flow Meter

3. Flow Sensor

The following conditions must be satisfied to get the full benefit of the

MagFlux® flow sensor.

Minimum conductivity

• The conductivity of the media must be greater than 5 µS/cm.

Liner selection

• Use Teflon® lining for chemicals and food industries

• Use hard rubber lining for drinking water and waste water

• Use soft rubber lining for water with abrasive particles

Electrode selection

• Steel AISI 316TI-1.4571 for general purpose, sewage, water and district
heating systems

• Hastelloy for sea water

• Titanium and platinum for chlorine and other aggressive chemicals

Mounting location

• To obtain a stable and accurate flow measurement, it is very important
that the flow sensor is mounted correctly in the pipe system

• There must be no flow fluctuations

• Avoid locations where vacuum can occur; especially for flow sensors
with Teflon™ linings

• Avoid locations with vibrations from for example pumps

• Avoid locations with extensive temperature changes

• Avoid corrosive environments and locations with a great risk of con­densation, or consult factory for special builds for these locations

• Take care that condensate and water cannot enter the connector box
on the flow sensor.

• There must be sufficient free space around the flow sensor.

• IMPORTANT: Observe that the correct flow direction is set in the

MagFlux

flow direction is "A" (flow direction towards left).

®

"Converter Setup" menu and in the "Service Menu". Default

15

FW: 842018/842009

Electromagnetic Flow Meter

The flow directions A or B are clearly shown on the name plate. Default
flow direction is "A".

Pressure loss

The pressure loss can easily be determined, if the nominal pipe diameter is
greater than the MagFlux® flow sensor. See the diagram below:

Pressure loss graph

0.003

The diagram illustrates that decreasing the internal diameter from 100 mm
(DN) to 80 mm (DO) will cause a pressure loss of 0.003 Bar @3 m/s.

16EN 3.05 MagFlux Manual 1212

Electromagnetic Flow Meter

10 m/s

Accuracy

According to the type and size of the flow sensor, the measuring accuracy
will be better than 0.25%, provided that the flow sensor has the correct
dimension.

[%]

5

4

3

2

1

0,20,10 0,5 21 5

Sizing

The flow sensor should be selected so the flow velocity through the sensor
will be between 0.2 - 10 m/s.

MJK recommends that flow velocities in tubes are kept between 1 - 3 m/s
for reliable and safe operation. See also the dimensioning table below and
the dimensioning chart on the following page.

Min and max flow

DN

3 5.09 254 20 226 11304 65 2,39 119
6 20.4 1018 25 353 17676 80 3,62 181

8 36.2 1810 32 579 28944 100 5,65 283
10 56.5 2827 40 905 45360 125 8,84 442
15 127 6362 50 1414 70560 150 12,7 636

Min and max flow

DN

200 22.6 1131 450 115 5726 900 458 22902
250 35.3 1767 500 141 7069 1000 565 28274
300 50.9 2545 600 204 10179 1200 814 40715
350 69.3 3464 700 277 13854 The Qmax. is equal to 20 mA
400 90.5 4524 800 362 18095

Qmin Qmax

0.2 m/s 10 m/s 0.2 m/s 10 m/s 0.2 m/s 10 m/s

[l/h] [l/h] [l/h] [l/h] [m

Qmin Qmax

0.2 m/s 10 m/s 0.2 m/s 10 m/s 0.2 m/s 10 m/s

3

/h] [m3/h] [m3/h] [m3/h] [m3/h] [m3/h]

[m

DN

DN

Qmin Qmax

Qmin Qmax

17

Qmin Qmax

DN

3

Qmin Qmax

DN

factory preset

FW: 842018/842009

/h] [m3/h]

Electromagnetic Flow Meter

DN 1000 - 40"

DN 900 - 36"

DN 800 - 32"

DN 700 - 28"

DN 600 - 24"

DN 500 - 20"

DN 450 - 18"

DN 400 - 16"

DN 350 - 14"

DN 300 - 12"

DN 250 - 10"

DN 200 - 8"

DN 150 - 6"

DN 125 - 5"

DN 100 - 4"

DN 80 - 3"

DN 65 - 2 1/2"

DN 50 - 2"

DN 40 - 1 1/2"

DN 32 - 1 1/4"

DN 25 - 1"

DN 20 - 3/4"

DN 15 - 1/2"

DN 10 - 3/8"

DN 8 - 5/16"

DN 6 - 1/4"

DN 3 - 1/8"

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

0,9

1

2

3

4

5

6

7

8

9

10

0, 2

0, 3

0, 4

0, 5
0, 6
0, 7

0, 8
0, 9

1

2

3

4

5
6
7

8
9

10

20

30

40

50
60
70

80
90

0, 02

0, 01

0, 03

0, 04

0, 05
0, 06
0, 07

0, 08
0, 09

0, 1

20 000

30 000

10 0

20 0

30 0

40 0

50 0

60 0
70 0
80 0
90 0

10 00

20 00

30 00

40 00

50 00

60 00
70 00
80 00

90 00

10 000

1,5

Sizing Chart

Example: A MagFlux with an internal diameter of 100 mm can measure
flow rates between approx. 290m3/h and 5.6 m3/h, and the fluid velocity is

1.5 m/s at a flow rate of approx. 42 m3/h.

Fluid velocity [m/s]

Size

3

/h]

Flow [m

18EN 3.05 MagFlux Manual 1212

Electromagnetic Flow Meter

3

2

3

2

3

2

Pipe System

1. The flow sensor must be mounted in a location which is free from inter­fering elements like valves, Ts, bends, pumps, etc. to ensure a laminar
flow without turbulence upstream of the flow sensor. For that reason
the flow sensor must be mounted in a straight pipe at a distance from
interfering elements of minimum 3 x DN upstream and minimum 2 x
DN downstream.

Flow direction

Flow direction

Flow direction

Important: Valves should always be mounted on the downstream side

of the flow sensor!

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Electromagnetic Flow Meter

2. If it becomes necessary to use reducers, the inner angle must not

exceed 7.5°.

The minimum length to keep the angle below 7.5° can be checked by

means of the formula below:

L = (D - d) x 7.63

where "D" is the large diameter and "d" the small diameter of the re-

ducer.

Example: If a flow sensor in dimension DN 80 is mounted downstream

of a 100 mm pipe, the reducer must then have a length of minimum
152,6 mm in order to keep the inner angle below 7,5 °.

3. Flange connections must be assembled concentrically on both the up-

stream and the downstream side. Measuring accuracy will be affected
by turbulence in the liquid from poorly made connections.

Important: Gaskets and grounding rings must also be mounted con-

centrically!

4. The flow sensor should always be filled with liquid. For that reason the

flow sensor must not be mounted at the highest point of the pipe sys­tem or in free outlets, where gravity could empty or partially empty the
pipe.

20EN 3.05 MagFlux Manual 1212

Electromagnetic Flow Meter

5. The flow sensor can be mounted vertically or horizontally.

If the flow sensor is mounted vertically, the flow direction should always

be upwards. In that way the effect from possible bubbles in the liquid
will be significantly reduced, just as it will ensure that the flow sensor is
always filled with liquid.

In case the liquid is carrying particles, for example when measuring

sludge, sewage, etc., the flow sensor must be mounted vertically.

6. When mounting horizontally in pipes with free downstream outlet, the
flow sensor should be mounted such that it will always be filled with liq­uid, for example in a bend situated lower than the height of the outlet.

In case the liquid is carrying particles, e.g. when measuring sludge,

sewage etc. the flow sensor must be mounted vertically.

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FW: 842018/842009

Electromagnetic Flow Meter

7. When mounting horizontally the flow sensor can be rotated max. +/- 45°

seen from the connection end. If the flow sensor is rotated more than
45°, one of the electrodes may not be in full contact with the liquid.

Cabinet Mounted on the Flow Sensor

The cabinet is mounted on the flow sensor with four pcs. 6x12 hex cap
screws.

22EN 3.05 MagFlux Manual 1212

Electromagnetic Flow Meter

Potential Equalization and Grounding

Type 7100/7200/7600 in Conductive Pipes

Conductive pipes

Equalization connection

Soft gasket

Ground connection.

NB! The flow sensor must be connected to an effective ground
connection, and the wire dimension must be at least 1.5 mm

Type 7100/7200/7600 in Non-conductive Pipes

2

.

Non-conductive pipes

Grounding ring (Min. thickness = 5 mm.)

Potential equalization connection

Soft gasket

Ground connection.

NB! The flow sensor must be connected to an effective ground
connection, and the wire dimension must be at least 1.5 mm

23

2

FW: 842018/842009

.

Electromagnetic Flow Meter

Type 7300/7400 in Conductive Pipes

Potential equalization connection

Conductive pipe

Ground connection.

NB! The flow sensor must be connected to an effective ground
connection, and the wire dimension must be at least 1.5 mm

Type 7300/7400 in Non-conductive Pipes

Grounding ring (Min. thickness = 5 mm.)

Potential equalization connection

Soft gasket

Soft gasket

Conductive pipe

2

.

Soft gasket

Non-conductive pipe

Ground connection.

NB! The flow sensor must be connected to an effective ground
connection, and the wire dimension must be at least 1.5 mm

24EN 3.05 MagFlux Manual 1212

Non-conductive pipe

2

.

Electromagnetic Flow Meter

521255

Ground from

flow pipe

Red

White

White

Black

Green

White

L2E2E1

L1GND

Mains

supply

-mA--RE2--RE1--DI1--Display-

+ +A B DI COM CNO NO PE N L

- -

FUSE

www.mjk.com

Fuse rating: 100 mAT @ 115 V AC

63 mAT @ 230 V AC

521254

Connection for top

mounted operator panel

Live

Neutral

Protective earth

PE N L

Terminals

for remote

operator panel

+ A B

-

Up to four MagFlux® flow sensors can
be connected to one operator panel:

4 wire cable.2 wire cable.

A, B

+, A, B,

-

4-20 mA (Active.)

Max. 500 Ω

Electronic relay

Max. 50 V 120 mA resistive load

Mechanical relay

Max. 50 V 1A resistive load

< 5 VDC = O ; > 10 VDC = I

Max. 30 VDC

+DI COM COMNO NO

-

DO1DI DO2 AO

FUSE

MAINS SUPPLY

Sensor #1

Sensor #4

Operator

panel

4. Flow Converter

Electrical Mounting

Warning: The MagFlux® flow converter / flow sensor must not be
mounted in explosion hazardous areas!

Loosen the four screws (position indicated by arrows) and remove the
display unit to gain access to the terminals.

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FW: 842018/842009

Electromagnetic Flow Meter

Power Supply

The flow converter must be supplied from a properly fused mains outlet, a
24 volt AC outlet, or a 10 - 30 V DC power supply/battery.

Power Supply 230 V AC, 115 V AC or 24 V AC

Terminal Designation

PE Protective ground

N 230 / 115 / 24 V AC neutral

L 230 / 115 / 24 V AC live

Power Supply 10 - 30 V DC

Terminal Designation

PE Protective ground

— DC neutral

+ DC live

The internal fuse ratings are:

Internal Fuse Ratings

Voltage Rating Order no. Dimension

230 V AC 0.063 mA T 550030 5 x 20 mm

115 V AC 0.125 mA T 550035 5 x 20 mm

24 V AC 0.5 mAT 550049 5 x 20 mm

10 - 30 V DC 1.0 AT 550051 5 x 20 mm

The technical specifications/requirements for a 10 - 30 V DC power
supply/battery are:

Technical Specifications for 10 - 30 V DC Power Supply

Power consumption without display < 5 W

Power consumption with display < 8 W

Peak start current @12 V DC,1 second Approx. 1,5 A

Peak start current @24 V DC,1 second Approx. 1 A

26EN 3.05 MagFlux Manual 1212

Electromagnetic Flow Meter

Changing the Power Supply Voltage 230/115 V AC

To change the input mains voltage from 230 VAC to 115 VAC (or vice
versa) proceed as follows:

1. Loosen the four screws on the front and lift out the display (see also
page 25).

2. Note down the color and position of the wires in the terminal blocks,
and then loosen the terminal screws.

3. Unscrew the two screws that hold the metal cover and then remove it.

4. Unscrew the four screws that hold the mother PCB (the printed circuit
board with all the electrical components).

5. Remove the mother PCB and look at the back side. This is what you
should see (230 V AC configuration):

6. Unsolder and remove the jumper indicated by the arrow.

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FW: 842018/842009

Electromagnetic Flow Meter

7. Look at the following picture to see where two new jumpers must be

inserted (115 V AC configuration):

8. Insert and solder 2 jumpers (wires) in the positions indicated by the ar-

rows.

9. Turn around the PCB and replace the 63 mAT fuse on the right side

with a 125 mAT fuse ( or vice versa going from 115 VAC to 230 VAC).

10. Re-insert the PCB and re-assemble the flow meter (see also steps 4, 3,

2 and 1).

28EN 3.05 MagFlux Manual 1212

Electromagnetic Flow Meter

Analogue Output

The analogue output is an active output with a max. load of 800Ω.

Analogue Output

Terminal Designation

AO + 4-20 mA
AO

-

4-20 mA

The analogue output can be programmed for indication of:

- direct flow

- inverse flow

- bidirectional flow

- absolute flow

See details on pages 63 - 66 incl.

Digital Outputs

MagFlux® has two digital outputs - DO 1 with an opto (light triggered)

relay and DO 2 with a mechanical relay.
They can both be programmed for the following functions:

- high and low flow alarms

- pulse output for counters R Totalizer Forward and Reverse

- batch 1 and batch 2 counters

- system error alarm

- empty pipe alarm

- flow direction indication

Opto Relay (DO1)

Terminal Designation

DO 1 Com Max. 50 V DC /120 mA
DO 1 NO

Mechanical Relay (DO2)

Terminal Designation

DO 2 Com Max. 50 V DC /1 A
DO 2 NO

DO 1 shares the common terminal (Com) with DI.

29

FW: 842018/842009

Electromagnetic Flow Meter

See also application examples in Appendix G. Digital Input/Output Con­nections on page 123.

Digital Input

MagFlux® has one digital input which is activated with a voltage higher

than 10 V DC and de-activated with a voltage lower than 5 V DC.

Digital Input

Terminal Designation

DI Com
DI Max. 30 V DC

The digital input (DI) can be programmed for the following functions:

- start and pause batch 1 and batch 2 counters

- reset counters R Totalizer Forward and Reverse

- reset counter R Totalizer Sum
DI shares the common terminal (Com) with DO 1.
See also application examples in Appendix G. Digital Input/Output Con-

nections on page 123.

Local (compact) Flow Sensor

Connect the compact (local) flow sensor to the flow converter with the
wires coming from the flow sensor as shown below.

Compact Flow Sensor

Terminal Signal Designation Colour from sensor

1

2 E1 Electrode Red

3 E2 Electrode White

4 GND Ground Black

5 L1 Coil Blue

6 L2 Coil Brown

7, 8 and 9 not used

Liquid GND

Built-in liquid
ground electrode

30EN 3.05 MagFlux Manual 1212

Black/shield