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CE-2424 An ISO 9001:2008

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OPERATING MANUAL

MODEL: ELECTROMAG

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Cautions!

IMPORTANT STORAGE AND HANDLING INSTRUCTIONS

1) Do not lift the Flowmeter by the Transmitter or Junction box.

2) When the Flowmeter is in unused condition, the cable gland holes must be adequately
closed to avoid Ingress of moisture which could lead to problems in Electronic circuitry
3) Do not roll or drag the unit on the lining on the flange which will damage the lining.
4) For Flowmeters above size DN 125, do not lift it by its case. Use eye bolts provided.
5) Rest your Flowmeter only in its upright position on the pedestals provided and not on
the casing.
6) When Flowmeter is not in use for extended period, empty the Flowmeter by draining the
liquid.
7) While storing cover the flanges by earthing rings and wooden covers to protect lining
from any damage.

INDEX

1. Introduction……………………………………………………………………03
2. Applications…………………………………………………………………...03
3. Installation……………………………………………………………………..04
3.1 Mechanical Installation
3.2 Electrical Installation
3.3 Installation Check Points
4. Operation………………………………………………………………………08
5. Display…………………………………………………………………………09
5.1 Run Mode
5.2 Diagnostic Mode
5.3 Clear Mode
5.4 Program Mode
6. Operational Precautions……………………………………………………..17
7. Troubleshooting……………………………………………………………....18
7.1 Troubleshooting for Flow Tube
7.2 Troubleshooting for Transmitter
8. Drawings…………………………………………………………………….....21

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1. INTRODUCTION

Principle of Operation (Ref. Fig. 1)

The Electromagnetic Flowmeters are based on Faraday’s law of
Electromagnetic induction. In Electromagnetic Flowmeter, magnetic field is
generated by a pair of coils. As the conductive liquid passes through the
Electromagnetic field an Electric voltage is induced in the liquid, which is
directly proportional to its velocity. This induced voltage is perpendicular to
both the liquid Flow direction and the Electromagnetic field direction. The
voltage sensed by the Electrodes is further processed by the Transmitter to a
give standardized output signal.The flux density of Electromagnetic field in a
given Flowmeter and the distance between the Electrodes are constant.
Therefore the induced voltage is only a function of liquid velocity.
E = K. B. v. D. where E = Induced Voltage
B = Magnetic Field Strength
K = Flow Tube Constant (Meter Constant)
v = Mean Flow Velocity
D = Electrode Spacing
Volume Flow is calculated by equation,
qv = (ð x D² /4 ) x v

Therefore,
qv = (ð x E x D ) / 4 K B
The induced voltage is not affected by the physical properties of the liquid like
temperature, viscosity, pressure, density and conductivity, as long as
conductivity of the measured liquid is above a minimum threshold level.

For reliable measurements the pipe must be completely full of liquid. The
Electromagnetic field coils are excited by pulsed DC technique, which
eliminates the interfering noise and provides automatic zero correction.

2. APPLICATIONS
Chemical and Process Industries
Fertilizer Industries
Pharmaceutical Industries
Sugar and Beverage Industries
Paper and Pulp Industries
Aluminum and Steel Industries
Mining and Dredging Industries
Polymer Industries
Water and Waste Water Management

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3. INSTALLATION

Inspection
Before installing the Flowmeter, check for mechanical damage due to possible
mishandling during shipping. All claims for damage are to be made promptly
prior to installation.

Primary Requirement
The Flowmeter and the signal cables should not be installed in close proximity
to strong Electromagnetic fields. The Flowmeter must be installed in such a
way that the meter tube is always completely filled with fluid and cannot drain. A
slight upward slope of approx. 3% is desirable to prevent gas build up within the
Flowmeter. (Ref. Fig. 2 for various installation locations) Up and Downstream
of the Flowmeter primary straight pipe sections are to be installed with the
same inside diameter as the inlet opening of the Flowmeter. Upstream of the
Flowmeter the length must be at least 5 times the diameter of the Flowmeter
and the downstream length must be at least 3 times the diameter of the
Flowmeter.(Ref. Fig. 4) .

3.1 Mechanical Installation

Flow Tube Installation

The Electromagnetic Flowmeter can be installed at any arbitrary location in the
pipeline as long as the installation requirements are satisfied. Installation
dimensions may be found in the appropriate Specification Sheet. At the same
time, care should be exercised when selecting the installation site to assure
that moisture cannot enter into the connection area. Exercise cares to assure
that the housing cover gaskets are correctly seated when installing the covers
after the installation and start-up have been completed.

Torque Specifications for Flanges

The mounting bolts are to be tightened equally in the usual manner without
excessive onesided tightening. We recommend that the bolts be greased prior
to tightening and that they be tightened using a wrench with a normal length, in
a crisscross pattern. Tighten the bolts during the first pass to approx. 50%,
during the second pass to approx. 80% and only during the third pass to 100%
of the max. torque value. The max torque values should not be exceeded, see
the following tables.

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Tightening Torque in Newton-Meters (NM)

After installation of the Flow Tube, gradually fill the pipeline with the liquid
preferably water instead of process liquid to ensure leak free installation. If it is
still leaking, cleanliness of gasket material and rating of gasket material should
be checked. After removing the leakages, process fluid may be passed
through the pipeline.

Flow Tube Local Earthing / Grounding

For proper working of the Flowmeter grounding as mentioned in Fig. 10 is very

important. For accurate measurement, with Electromagnetic Flow measuring
technique, an efficient grounding of primary head is necessary. This ground is
the reference ground for the measurement and should not add any
interference to the signal to be measured. Use 2.5 sq.mm or higher cable for
earthing. To ensure interference free operation, no other Electrical
appliance should be connected to this ground. This ground performs the
function of safety ground also.

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Mechanical Installation of Transmitter

If Transmitter is of integral type as per your order, it comes mounted on the Flow
Tube and gets installed with Flow Tube in the above procedure. If Transmitter is
remote type, the Terminal/ Junction box is fitted on the Flow Tube. The
Transmitter along with the mounting bracket comes separate. The mounting
bracket is suitable for 2” NB pipe mounting on vertical, horizontal or wall
mounting. Figure 6 shows different methods of mounting the Transmitter ona
pipe or wall. The Transmitter can be turned around on the mounting bracket in
suitable viewing direction around the vertical axis. Provide a canopy to Flow
Transmitter Housing to avoid direct exposure
to Sunlight and Rain.

3.2 Electrical Installation

Integral Transmitter (Ref. Fig. 7)

1) The integral Transmitter is mounted on the Flow Tube with coil and Electrode
connections done.
2) Open the cover of Terminal compartment of the Transmitter.
3) Connect proper power supply as indicated on tag plate to proper Terminals
marked L, N and E in the Terminal box. The cable gland of ½” NPT size double
compression type should be used to insert the cable inside the Terminal box.
This will ensure environmental protection of Transmitter housing.
4) Connect output cable to the output Terminals marked 4 – 20 mA DC with
polarity marking and take the cable through gland for above reasons. Signal
and Mains cable should be run in separate conduit. Refit the Transmitter
Terminal box cover.

Remote Transmitter (Ref. Fig. 7)

1) In case of remote Transmitter, the Terminal/Junction box is fitted on the Flow
Tube.
2) Open the Terminal compartment cover of the Transmitter and Terminal box
on the Flow Tube. The Terminals in both the compartments are marked for
proper wiring.
3) Connect proper power supply to the supply Terminals as indicated by L, N
and E in the Terminal compartment of the Transmitter. Connect output cable to
output Terminals marked I + and I - .(Ensure proper polarity for other end of the
cable to any indicator or in any control loop connect the cable)
4) Connect the cable supplied for Electrode cabling between E1, E2 and G of
Transmitter Terminal Compartment to E1, E2 and G respectively in the
Terminal box on the Flow Tube.

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5) The maximum permissible cable length of Electrode cable is 10 meters. Also

connect coil Terminals marked C1 and C2 in the Transmitter Terminal
compartment to Terminals marked C1 and C2 respectively in the Terminal box
on the Flow Tube.
6) Use separate cable gland for Main Supply Cable, Output Cable, Electrode
Cable and Coil Cable. Also bring out Electrode and coil cables through the
separate cable glands in the Terminal box. Refit the Transmitter cover and the
Terminal box cover.
7) Under no circumstances should the signal cable run in close proximity to any
other power cable.
8) The cable length should be as short as possible. The total load capacity of
the Transmitter inducing cable load and other instrumental loads is 1000
Ohms. The output is isolated.

3.3 Installation Check Points

1.Is the liquid to be measured compatible with the lining and Electrode
materials?
a) If the liquid to be measured is a mixture of the liquids, the compatibility of all
liquids with Electrode and lining should be confirmed. Many process liquids are
designated by generic names. But it may contain the contaminations in traces.
These traces may also be harmful to the Flowmeter.
b) Beside the corrosion of materials depends upon the temperature and the
concentration of the liquid.
c) The corrosion due to service liquid will reduce the life of the Flowmeter.
2. Is the Flowmeter rated for the supply voltage and frequency available?
3. Is the Flowmeter suitable for the Flow rate being measured? I.e. the velocity
in normal conditions should be above 1 m/sec. and should not exceed 10
m/sec.
4. Is the Flowmeter completely filled with liquid? (No gas bubbles are flowing
with the liquid)
5. Is the installation wired properly as per the diagrams in this manual?
6. Is the grounding done as specified?

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4. OPERATION
After completion of installation as stated above, the Flowmeter is ready for use.

Switch ON the power supply. The Flowmeter will give output signal
proportional to the Flow rate of the liquid in the pipe line as per set velocity of the
Flowmeter. Tag plate fitted on the Transmitter indicates the maximum Flow rate
for which the Flowmeter has been calibrated.

If Flow more than the set velocity is passed through the Flowmeter, the output
signal will be more than 20 mA DC.The current saturates at about less than 30
mA DC. The current more than 20 mA may not represent the actual Flow rate
accurately.

The Flow beyond the maximum Flow rate may damage the Flowmeter lining.

The Ten Turn potentiometer with dial indicator is provided on PCB PC 9502
(Ref. Fig. 8) for full scale velocity setting. The output will be 20 mA DC for the
Flow velocity set by the potentiometer. The velocity can be set from 0 to 10
m/sec. The set velocity dial resolution is 0.02 rotations (50 divisions per
rotation of setting knob).Thus, the velocity can be set with resolution of 0.02
m/sec. The integral portion of the velocity setting is visible in the window on
the dial indicator and the frictional portion is on the circular dial.

Flow rate at 20 mA DC output will be:

Velocity setting of Potentiometer X Flow rate of Flowmeter at 1 m/sec.
Note:

The Product Technical Datasheet gives Flow rates of Flowmeters at 1

m/sec, depending on the DN Size.

The facility of full scale velocity potentiometer is very useful for getting better
accuracy results for the actual Flow rate. To clarify the use of velocity
potentiometer, let us use an example DN 50 Flowmeter.

Suppose actual Flow is 175.2 LPM through the Flowmeter.

At 1 m/sec velocity the Flow rate in Flowmeter DN 50 size will be 117.81

LPM

Thus, the Flow velocity will be 175.2 / 117.81 = 1.4871 m/sec.

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Set Velocity x Flow Rate at 1 m/sec If velocity potentiometer is set at 10 m/sec,

the output current at 175.2 LPM will be 6.38 mA Flow velocity being less than 20
% of full scale velocity the accuracy will not be better than 1%

To get better accuracy, if velocity potentiometer is set to 2 m/sec (235.62 LPM),

the output current will increase to 15.90 mA for 175.2 LPM. Also Flow velocity
will be higher than 20 % of full scale velocity, thus, the output will be accurate
within 1% of actual Flow.

By this way effectively we get wide range of Flow rate with accuracy of better
than 1% of actual Flow rate from 0.1 m/sec. velocity range.

5. DISPLAY
A 16 X 2 LCD is provided for indication of Flow Rate and Totaliser.
The Flow Rate and Totaliser can be viewed in engineering units according to
your choice.

3 Tactile Keys are provided below Display for Configuration purpose.

(Ref. Fig. 12)

Use above keys is described in various Run and Configurations screens.

A standard fixed Password ‘4321’ is used.

Run Mode Operation, Configurations are explained in the following Flow

charts.

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5.1 Run Mode: Various Run Mode Screen Options are available.

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5.2 Diagnostic Mode

Current Firmware Version, On and Run Hours can be viewed. On Hours inform
the time for which Flowmeter is on and Run Hours indicate the Flow Hours. INT
indicate Power Fail Interruptions and T OF indicate numbers of Totaliser
overflow.

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5.3 Clear Mode

Totaliser, On & Run Hours can be cleared. This mode is password protected.

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5.4 Program Mode:

In Program Mode, Flowmeter related settings can be edited or read.

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Flowmeter Settings Read/Edit Mode

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1) If user enters Edit or Read Mode, in all 4 sub menus are available. FLOW,
DISP.

2) Under FLOW sub menu, Flowmeter related settings such as DN Size, Flow
Rate, Flow Rate time base (such per Second, Minute,Hour) Flow Unit, Total
Unit, Totaliser Resolution, %Clip can be viewed or edited.

3) The procedures for editing is explained on the right hand side of the chart.

4) Under DISP sub menu, Totaliser, Velocity can be enabled or disable for
viewing. Based on the selections, different run mode screens will appear.
Automatic Scrolling will be enable for more than one parameter selected for
Run Mode. The scrolling time can also be set.

5) The structure of Read and Edit is identical. Modification is possible only in

edit mode.

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DISP Screens

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6. OPERATIONAL PRECAUTIONS

1) Though the Terminal Box of the Flowtube is designed to work under Field
conditions, we recommend it to protect it from open Sunlight/rains etc. to get
extended life.

2) Maintain the colour of the Flowmeter by applying colour periodically to get

extended life.

3) Take proper care of the cables and avoid any stretching or breaking of the
cables.Keep the cable glands tight so as to avoid moisture entering in the
Terminal box or Transmitter.

4) Connect proper Supply Voltage to get the desired accuracy and the life.

5) The liquid Flowing through Flowmeter should be free of abrasive slurry or

particles if Flow rate is near its full scale. If liquid contains any type of abrasives,
Flow rate should be limited to 3 m/sec. to avoid damage to the lining.

6) No strong magnetic field should exist in the vicinity of the Flowmeter. The
magnetic field may modify the output signal of the Flowmeter.

7) Proper grounding should be maintained for accurate operation of Flowmeter

This can be checked by checking zero of Flowmeter, in following way: Stop the
Flow of liquid by using control valve downstream of the Flowmeter. In such
case Flowmeter will remain full of lquid. Keep the power supply to the Flow
meter ON. Measure the output signal by using accurate 3 ½ Digital multimeter.
The output should be within 4 ± 0.01 mA DC.

If not, possible reasons are: a) Improper Ground

b) Contaminated Electrodes
c) Shifted Zero preset

The pulsed DC excitation of field coils ensure stable zero / auto zeroing if all
other conditions are satisfactory.

8) Liquid Flowing should be without any gas bubbles. Gas bubbles will give
misleading output.

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7. Troubleshooting

Contuned in Next Page ...............

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Contuned in Next Page ...............

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Important Check Points in Troubleshooting

1) Output current saturated

a) Reverse Flow direction at 3.4 mA DC approx.
b) Reverse coil wiring

2) Output current saturated a) Flow rate higher than set by velocity

potentiometer at about 26.5 mA DC b) Electrode open

3) Output not 4 mA DC
a) Confirm whether Zero Flow is present at No Flow condition
b) Trickle Flow present
c) Grounding not proper
d) Zero adjust preset P3 on PC 9502 disturbed

4) Output current not steady

a) Flow not steady
b) Gas / air bubbles in the Flow
c) Varying Conductivity
d) Grounding not proper

5) “Err” Displayed
a) E1/G/E2 Wire Connections are open
b) Reverse Flow
c) Actual Flow Rate Higher than the set Rate
d) C1/C2 Connections are open

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