ABB 10D1476 User manual

INSTRUCTION MANUAL
MAGNETIC FLOWMETERS
10D1476 Design Level S
1/25 - 4 in.
K-MAGMAGNETIC FLOWMETER
PN25009A

The following are trademarks of ABB Inc.: K-MAG
MAG-X
The following is a trademark of E.I. DuPont de Nemours & Company: TEFLON-FEP
The following is a trademark of Haynes International Incorporated: HASTELLOY
The following is a trademark of Richard Klinger, Incorporated: KLINGER SIL C-4401
The following is a registered trademark of Ladish Company, Tri-Clover Div: TRI-CLAMP
The following is a registered trademark of Garlock Incorporated: GYLON
The following is a registered trademark of Rosemount Incorporated: HART
WARNING notices as used in this manual apply to hazards or unsafe practices which could result in personal in-
jury or death.
CAUTION notices apply to hazards or unsafe practices which could result in property damage.
NOTES highlight procedures and contain information which assist the operator in understanding the information
contained in this manual.
All software, including design, appearance, algorithms and source codes, is owned and copyrighted by
ABB Inc. or its suppliers.
WARNING
INSTRUCTION MANUALS
Do not install, maintain or operate this equipment without reading, understanding and following the
proper ABB Inc. instructions and manuals, otherwise injury or damage may result.
POSSIBLE PROCESS UPSETS
Operation & maintenance must be performed only by qualified personnel and only after securing
equipment controlled by this product. Adjusting or removing this product while it is in the system may
upset the process being controlled. Some process upsets may cause injury or damage.
NOTICE
The information contained in this document is subject to change without notice. ABB Inc. reserves the
right to make minor changes to this publication, such as company name & logos as well as other minor
corrections, without necessarily changing the publication number.
ABB Inc., its affiliates, employees, and agents, and the authors of and contributors to this publication
specifically disclaim all liabilities and warranties, express and implied (including warranties of
merchantability and fitness for a particular purpose), for the accuracy, currency, completeness, and/or
reliability of the information contained herein and/or for the fitness for any particular use and/or for the
performance of any material and/or equipment selected in whole or part with the user of/or in reliance
upon information contained herein. Selection of materials and/or equipment is at the sole risk of the
user of this publication.
This document contains proprietary information of ABB Inc. and is issued in strict confidence. Its use,
or reproduction for use, for the reverse engineering, development or manufacture of hardware or
software described herein is prohibited. No part of this document may be photocopied or reproduced
without the prior written consent of ABB Inc.
Copyright 2003 ABB Inc. [October, 2003]

Table of Contents
SAFETY SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
READ FIRST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III
1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Model Number Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
2.0 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.3 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.3.1 Meter Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.3.2 Meter Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.3.3 Pipe Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.3.4 Basic Mounting Procedure, Standard Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.3.4.1 1 - 40 mm (1/25 - 1-1/2 inch) Meter Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.3.4.2 50 - 100 mm (2 - 4 inch) Meter Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.3.5 Mounting Procedure, Sanitary Coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.4 Grounding Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.4.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.4.2 Conductive Pipeline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.4.3 Non-Conductive or Insulated Pipeline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.5 Electrical Interconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
3.0 START-UP and OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
4.0 FUNCTIONAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 Basic Operating Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1.1 Signal Voltage Generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1.2 Magnet Coil Drive Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.1.3 Volumetric Flow Rate Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 Operating Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2.1 Liquid Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2.1.1 Liquid Conductivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2.1.2 Liquid Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.2.1.3 Other Liquid Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.2.2 Metering Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
5.0 Circuit Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 Primary Signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Constant Meter Factor (CMF) PC Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL
i

6.0 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.3 Static Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3.1 Magnet Coil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3.2 Electrode Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.3.3 Flowmeter Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
7.0 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Figure List
FIGURE 1-1. TYPICAL FLOWMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
FIGURE 1-2. ELECTRONICS COMPARTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
FIGURE 2-1. OUTLINE DIMENSIONS, SIZES 1/25" THROUGH 1-1/2" . . . . . . . . . . . . . . . . . . . . . . . . 2-2
FIGURE 2-2. OUTLINE DIMENSIONS, SIZES 2" THROUGH 4" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
FIGURE 2-3 OUTLINE DIMENSIONS, WITH SANITARY FITTINGS, SIZES 1/25" THROUGH 1-1/2" . 2-6
FIGURE 2-4 OUTLINE DIMENSIONS, WITH SANITARY FITTINGS, SIZES 2" THROUGH 4" . . . . . . 2-7
FIGURE 2-5. RECOMMENDED PIPING DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
FIGURE 2-6. FLANGE BOLT TIGHTENING SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
FIGURE 2-7. MOUNTING DIAGRAM FOR 1- 40 mm (1/25 - 1-1/2") SIZES . . . . . . . . . . . . . . . . . . . . 2-10
FIGURE 2-8. MOUNTING DIAGRAM FOR 50 - 100 mm (2 - 4") SIZES. . . . . . . . . . . . . . . . . . . . . . . . 2-12
FIGURE 2-9. MOUNTING DIAGRAM, SANITARY FITTINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
FIGURE 2-10. OUTLINE DIMENSIONS, GROUNDING RINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
FIGURE 2-11. GROUNDING PROCEDURE, NON-INSULATED PIPE . . . . . . . . . . . . . . . . . . . . . . . . 2-16
FIGURE 2-12. GROUNDING PROCEDURE, INSULATED PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
FIGURE 2-13. 10D1476S REMOTE CUSTOMER CONNECTION BOX . . . . . . . . . . . . . . . . . . . . . . . 2-18
FIGURE 3-1. TYPICAL INSTRUMENT TAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
FIGURE 3-2. ADDITIONAL TAG FOR FM APPROVED METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
FIGURE 3-3. PRIMARY MOUNTED PC ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
FIGURE 4-1. BASIC OPERATING PRINCIPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
FIGURE 5-1. SCHEMATIC for PRIMARY WIRING, REMOTE CONVERTER . . . . . . . . . . . . . . . . . . . . 5-2
FIGURE 5-3. SCHEMATIC for CMF BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
FIGURE 7-1. EXPLODED VIEW, BASIC FLOWMETER PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Table List
TABLE 1-1. CAL FACTOR and CAPACITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
TABLE 2-1. RECOMMENDED BOLT TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
TABLE 6-1. PRIMARY COIL RESISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
TABLE 7-1. ANSI CLASS 150 GROUNDING RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
TABLE 7-2. GASKETS FOR ANSI CLASS 150 GROUNDING RINGS. . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
TABLE 7-3. GASKETS FOR METER BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
TABLE 7-4. BASIC METER PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL
ii

SAFETY SUMMARY
GENERAL
WARNINGS
POSSIBLE PROCESS UPSETS
Maintenance must be performed only by qualified personnel and only after
securing equipment controlled by this product. Adjusting or removing this
product while it is in the system may upset the process being controlled.
Some process upsets may cause injury or damage.
RETURN OF EQUIPMENT
All Flowmeters and/or Signal Converters being returned to ABB Inc. for
repair must be free of any hazardous materials (acids, alkalis, solvents,
etc.). A Material Safety Data Sheet (MSDS) for all process liquids must
accompany returned equipment. Contact ABB Inc. for authorization prior to
returning equipment.
INSTRUCTION MANUALS
Do not install, maintain or operate this equipment without reading, under-
standing and following the proper ABB Inc. instructions and manuals, other-
wise injury or damage may result.
ELECTRICAL SHOCK HAZARD
Equipment powered by AC line voltage presents a potential electric shock
hazard to the user. Make certain that the system power is disconnected from
the operating branch circuit before attempting electrical interconnections or
service.
SPECIFIC
WARNINGS
ELECTRICAL SHOCK HAZARD
Equipment powered by AC line voltage presents a potential electric shock
hazard to the user. Make certain that the system power is disconnected from
the operating branch circuit before attempting electrical interconnections or
service. (Pg. 2-18)
All Flowmeters and/or Signal Converters being returned to ABB Inc. for
repair must be free of any hazardous materials (acids, alkalis, solvents,
etc.). A Material Safety Data Sheet (MSDS) for all process liquids must
accompany returned equipment. Contact ABB Inc. for authorization prior to
returning equipment. (Pg. 6-1.)
Equipment powered by an ac line voltage presents a potential electric shock
hazard. Servicing of the Magnetic Flowmeter or Signal Converter should
only be attempted by a qualified electronics technician.
(Pg. 6-2)
Equipment that operates from ac line voltage constitutes a potential electric
shock hazard to the user. Make certain that the system power is discon-
nected before making the following ohmmeter checks.
(Pg. 6-3)
SPECIFIC
CAUTIONS
Do not use a dc ohmmeter for this measurement as polarization effects will
produce completely erroneous data. (Pg. 4-3)
10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL
I

GÉNÉRAUX
AVERTISSEMENTS
PROBLÈMES POTENTIELS. La maintenance doit être réalisée par du
personnel qualifié et seulement après avoir sécurisé les équipements
contrôlés par ce produit. L’ajustement ou le démontage de ce produit
lorsqu’il est lié au système peut entraîner des dysfonctionnements dans
le procédé qu’il contrôle. Ces dysfonctionnements peuvent entraîner
des blessures ou des dommages.
RETOUR D’ÉQUIPEMENT. Tout débitmètre et(ou) convertisseur re-
tourné à ABB Inc. pour réparation doit être exempt de toute trace de
produit dangereux (acide, base, solvant, …). Un certificat de sécurité
matériel doit être joint pour tous les liquides utilisés dans le procédé.
Contacter ABB Inc. pour autorisation avant renvoi du matériel.
MANUEL DE MISE EN ROUTE. Ne pas installer, maintenir ou utiliser
cet équipement sans avoir lu, compris et suivi les instructions et
manuels de ABB Inc., dans le cas contraire il y a risque d’entraîner
blessures ou dommages.
RISQUE DE CHOC ÉLECTRIQUE
Les équipements alimentés en courant alternatif constituent un risque
de choc électrique potentiel pour l’utilisateur. Assurez-vous que les
câbles d’alimentation amont sont déconnectés avant de procéder à des
branchements, des essais ou tests.
SPÉCIFIQUES
AVERTISSEMENTS
Tout débitmètre et(ou) convertisseur retourné à ABB pour réparation
doit être exempt de toute trace de produit dangereux (acide, base,
solvant, …). Un certificat de sécurité matériel doit être joint pour tous
les liquides utilisés dans le procédé. Contacter ABB pour autorisation
avant renvoi du matériel. (Pg. 2-18)
RISQUE DE CHOC ÉLECTRIQUE
Les équipements alimentés en courant alternatif constituent un risque
de choc électrique potentiel pour l’utilisateur. Assurez-vous que les
câbles d’alimentation amont sont déconnectés avant de procéder à des
branchements, des essais ou tests. (Pg. 6-1)
RISQUE DE CHOC ÉLECTRIQUE
Les équipements alimentés en courant alternatif constituent un risque
de choc électrique potentiel. La maintenance sur des équipements élec-
tromagnétiques ou des convertisseurs doit être effectuée par des tech-
niciens qualifiés. (Pg. 6-2)
RISQUE DE CHOC ÉLECTRIQUE
Les équipements alimentés en courant alternatif constituent un risque
de choc électrique potentiel. Assurez-vous que la puissance est décon-
nectée avant de procéder aux mesures de résistance suivantes.
( Pg. 6-3)
SPÉCIFIQUES
ATTENTIONS
N’utilisez pas un ohmmètre de C.C pour cette mesure car les effets de
polarisation produiront des données complètement incorrectes.
(Pg. 4-3)
10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL
II

READ FIRST
WARNING
INSTRUCTION MANUALS
Do not install, maintain, or operate this equipment without reading,
understanding and following the proper instructions and manuals,
otherwise injury or damage may result.
RETURN OF EQUIPMENT
All Flowmeters and/or Signal Converters being returned to the factory
for repair must be free of any hazardous materials (acids, alkalis,
solvents, etc). A Material Safety Data Sheet (MSDS) for all process
liquids must accompany returned equipment. Contact the factory for
authorization prior to returning equipment.
Read these instructions before starting installation;
save these instructions for future reference.
Contacting the Factory...
Should assistance be required with any of the company’s products, contact the following:
Telephone:
24-Hour Call Center
1-800-HELP-365
E-Mail:
[email protected]
10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL
III

The NEMA 4X rating applies to the meter body and electronics enclosure only. The following
accessories (if supplied) may not meet NEMA 4X unless specifically ordered as NEMA 4X:
•meter flanges
•meter installation hardware: studs, nuts, bolts
•enclosure mounting hardware for pipe or wall mounting
•conduit hardware
This product is painted with a high performance epoxy paint. The corrosion protection provided by
this finish is only effective if the finish is unbroken. It is the users’ responsibility to "touch-up" any
damage that has occurred to the finish during shipping or installation of the product. Special attention
must be given to: meter flange bolting, pipe mounting of electronics, conduit entries and covers that
are removed to facilitate installation or repair. For continued corrosion protection throughout the
product life, it is the users’ responsibility to maintain the product finish. Incidental scratches and other
finish damage must be repaired and promptly re-painted with approved touch-up paint. Provide the
model number and size of your product to the nearest ABB Inc. representative to obtain the correct
touch-up paint.
10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL
IV

1.0 INTRODUCTION
1.1 General
The Series 10D1476 K-MAGmagnetic flowmeter, shown in Figure 1-1, is an electromagnetic liquid
flow rate detector. The meter uses the characteristics of a conductive liquid to generate an induced
signal voltage, directly proportional to flow rate, as the liquid passes internal electrodes. The
resultant voltage is applied to a solid state electronics package that conditions it to an output signal
compatible with conventional receiving equipment.
The standard meter design provides a compact, very low power, obstructionless primary metering
element that bolts between flanges in a process pipeline. Pressure losses in this type of meter are
reduced to levels occurring in equivalent lengths of equal diameter pipeline, thus reducing or
conserving pressure source requirements as compared to other metering methods. The compact size
of the meter results in a light-weight unit that requires no additional support other than that used
normally on pipe runs.
The Series 10D1476 K-MAG complies with 3-A Sanitary Standards For Flowmeters For Milk and Milk
Products, Number 28-01*. As an option, for 3-A Sanitary applications, the K-MAG can be supplied
with TRI-CLAMP®sanitary adaptors for connection to the customer’s sanitary tubing system. In
addition, for USDA Meat and Poultry Equipment applications, the K-MAG is provided with USDA
accepted epoxy paint on all exterior surfaces, gaskets certified to FDA/USDA sanitary requirements
and TRI-CLAMP sanitary adaptors assembled to the meter with all stainless steel hardware.
* 3-A Sanitary Standards are formulated by the International Association of Milk, Food and Environmental Sanitarians, the
United States Public Health Service, Food and Drug Administration and the Dairy Industry Committee. The 3-A Sanitary
Standards Symbol Administrative Council verifies compliance to these standards and authorizes the use of the 3-A Symbol.
FIGURE 1-1. TYPICAL FLOWMETERS
1/2" (15 mm) Meter Shown
Typical for 1/25" - 1-1/2"
(1 mm - 40 mm) Sizes
2" (50 mm) Meter Shown
Typical for 2" - 4"
(50 mm - 100 mm) Sizes
10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL
1-1

This flowmeter can be used to meter either clean or dirty liquids. The meter may be used without
regard to the heterogeneous consistency of the measured liquid and is as independent of the
tendency to plug or foul as the pipeline in which it is mounted. By design, only the ceramic spool
meter body and electrodes are wetted parts, and will accommodate most acids, bases, water and
aqueous solutions.
Viscosity and density of the metered liquid have no effect on the measurement accuracy of the meter
and, therefore, signal compensation is not required. Metering limitations are confined to a minimum
threshold of electrical conductivity inherent to the liquid being metered. The degree of liquid conduc-
tivity has no effect upon the metering accuracy (as long as it is greater than the minimum level). The
liquid temperature and pressure are limited to the meter material specification limits. Refer to Section
1.3.
The meter body is a sealed section that bolts between the customer’s pipe line flanges. The
measuring electrodes that contact the process liquid have their ends flush with the inside of the meter
tube. For accurate results, the meter bore diameter must be centered in the pipeline. For the larger
size meters, spacer sleeves are slipped over the flange mounting bolts. The smaller size meters use
a unique centering device to center the meter. The centering device is shown in Figure 1-1.
FIGURE 1-2. ELECTRONICS COMPARTMENT
PRIMARY
CUSTOMER
CONNECTION
BOARD
10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL
1-2

With the exception of the primary board, the associated electronics package is called the signal
converter and is remotely mounted. Figure 1-2 shows the electronics compartment for the remote
signal converter. The remote mounted signal converter improves performance if 1) the vibration
specification is exceeded and/or 2) the process liquid temperature vs. ambient temperature exceeds
the value specified for that of an integral converter.
The signal converter also contains a magnet driver unit that is used to power the meter’s magnet
coils. The steady state magnetic field principle, referred to as the MAG-X design concept, provides
optimum zero point stability at an optimized frequency which is a submultiple of the power line
frequency.
For additional information, refer to Section 4.0.
1.2 Model Number Breakdown
Refer to the equipment’s data sheet or the data tag on the equipment for the model number of the
instrument furnished. The details of a specific number are as follows:
10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL
1-3

Model 10D1476S
10D1476 S H __ _ M 2 9 _ _Y __3 _A _1 _1 __2
Engineering Reference
Design Level
with 50XM Electronics S
Liner Material
Ceramic Spool H
Meter Size [Inches (mm)]
1/25 (1)
1/12 (2)
1/10 (3)
5/32 (4)
1/4 (6)
3/8 (10)
1/2 (15)
1 (25)
1-1/2 (40)
2 (50)
3 (80)
4 (100)
36
37
01
02
04
06
07
09
11
12
14
15
Flange Standard/Pressure Rating
ANSI Class 150
ANSI Class 300
BS10 Table D
BS10 Table E
BS10 Table F
DIN PN16
DIN PN40
U.S.D.A. Sanitary Tri-Clamp Fittings
P
Q
S
T
U
D
F
1
Electrode Material
Platinum M
Electrode Type
Flush 2
Flange Material
Flangeless Design 9
Safety Classification
w/o FM Approval (General Purpose)
FM Approved - Primary Flowmeter & Remote-mounted Signal
Converter: Nonincendive for Class I, Div 2, Gp A, B, C & D;
Electrodes Intrinsically Safe for Class I, Div 1, Gp A, B, C & D;
Outdoor Hazardous Locations, NEMA 4X.
U.S.D.A. Approved Meat & Poultry Equipment (Also certified
for F.D.A. & 3A Sanitary Applications)
A
K
N
10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL
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Model 10D1476S (Cont.)
10D1476 S H M 2 9 Y 3 A 1 1 2
Power Requirements
Remote Converter Y
Enclosure Classification
IEC 529 IP 65, NEMA 4X
Accidental Submergence, IEC 529 IP 67
30 ft. H2O/48 hr. (9 m H2O/48 hr.)
1
5
Fluid Temperature Range
up to 356oF (180oC) 3
Output Current
No output signal required A
Output Options
No Scaled Output Required 1
Communications Mode Over Data Link
Not Applicable 1
Coil Drive Frequency
7-1/2 Hz (60 Hz)
15 Hz (60 Hz)
DC 15 Hz (@60 Hz Line Frequency)
1
2
3
Additional Options
None 2
10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL
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1.3 Specifications
Power Requirements See Section 1.2 Model Number Breakdown
Power Consumption Refer to signal converter instruction manual for
power input requirements; typically, 30VA.
Flowmeter Characteristics
Meter Size/Flow Capacity See Table 1-1
Span Factory set at specified range between extremes
listed in Table 1-1; can be field adjusted.
Rangeability 100:1
Minimum Liquid Conductivity 5 µS/cm
System Accuracy
Flowrate Accuracy
Frequency Output < 2% Cal Factor
≥2% Cal Factor
±0.02% Cal Factor
±0.5% of rate
RFI Protection Class 2-abc-0.1% (10 V/m-20 to 1000 MHz) Per
SAMA Standard PMC 33.1-1978. Standard with
converters; not available with remote converter.
Environmental Limits
Enclosure Classification with
or without Signal Converter
IEC 529 IP65; NEMA 4X
Accidental Submergence IE 529 IP67, 30 feet H2O/48 h (9 m H2O/48 h)
Environmental Temperature Limits
at Flowmeter.
−40 to 150oF
(-40 to 65oC)
Process Limits
Temperature Limits, Process Liquid May not exceed 356oF (180oC)
Thermal Shock positive temp change, 212oF (100oC)
negative temp change, 158oF (70oC)
10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL
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NOTE
The temperature gradient between the liquid and the ceramic spool should
not exceed 212oF (100oC) when increasing the temperature or 158oF
(70oC) when cooling, to prevent cracking. For example, if the ceramic is at
a temperature of 20oC, liquids at 120oC can be handled. If the liquid tem-
perature is 180oC, the ceramic spool should be stabilized for approximately
5 minutes at 120oC before allowing it to increase to 180oC. A similar consid-
eration should be made when cooling. This is especially important when fol-
lowing SIP* (Steam-in-place) procedures.
* SIP procedures per pharmaceutical industry.
Pressure Rating
Meter
size
Temperature
38oC (100oF) 130oC (266oF) 180oC (356oF)
1 - 80 mm
(1⁄25 - 3 in)
5.11 MPa
(740 psi)
4.62 MPa
(699 psi)
4.43 MPa
(643 psi)
100 mm
(4 in)
2.00 MPa
(285 psi)
1.66 MPa
(240 psi)
1.45 MPa
(210 psi)
Vacuum Limit full vacuum at 180oC (356oF)
Meter Calibration Factor specified on primary data tag (equal to max flow
capacity in engineering units). This factor is
equivalent to a flow velocity of 33.33 ft/s in the
metering tube.
Physical Characteristics
Outline Dimensions, magnetic
flowmeter with or without
signal converter
Standard with Sanitary Fittings
1-40 mm (1/25 - 1-1/2") See Figure 2-1 See Figure 2-3
50 - 100 mm (2 - 4") See Figure 2-2 See Figure 2-4
Remote Mounted Signal
Converter
See signal converter instruction manual
Conduit Connections (2) 1/2" NPT internally threaded entrances in pri-
mary junction box
Meter Weight See signal converter instruction manual
Signal Converter Vibration
Limit
5 to 14 Hz, 0.20";
14 to 200 Hz, 1.5 g
10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL
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Materials of Construction
Meter Body (Spool) Ceramic, 99.5% Alumina
Electrode Assemblies (wetted) Platinum
Meter Housing carbon steel, all welded construction, epoxy finish
Housing End Rings 304 sst
Electronics Housing die cast aluminum, epoxy finish, 316 sst attach-
ment screws, 1/2 NPT conduit connections, gas-
keted covers
Installation Kit includes 2 gaskets, mounting studs and nuts,
flange adaptor device(s) as required.
Exception: Sanitary TRI-CLAMP Fittings
Meter is preassembled; all mounting hardware
(studs and nuts) and flanges are stainless steel.
Gaskets are TEFLON-FEP (Virgin). Gasket
manufacturer must provide certificate of compli-
ance as proof of U.S.D.A. approval and compli-
ance with 3A Sanitary Standards, Class-I
material.
TABLE 1-1. CAL FACTOR and CAPACITY
NOTE
The CAL FACTORS given below can only be used with Model 10D1476 De-
sign Levels B,C, M, N, P & S. For Meters manufactured under design level
A, refer to the meter data tag for the appropriate factor.
Flow Ranges
0 to value tabulated
Meter Size CAL
FACTOR*
Minimum
10D1476B & C
Minimum
10D1476M, N & P
Maximum
mm inch gpm gpm lpm gpm lpm gpm lpm
11⁄25 0.1610 0.014 0.06 0.009 0.03 0.18 0.60
21⁄12 0.5368 0.048 0.20 0.027 0.10 0.54 2.00
31⁄10 1.073 0.096 0.40 0.054 0.20 1.20 4.00
45⁄32 2.147 0.192 0.80 0.108 0.40 2.40 8.00
61⁄45.367 0.480 2.00 0.270 1.00 6.00 20.0
10 3⁄812.08 1.08 4.50 0.605 2.25 13.5 45.0
15 1⁄226.84 2.40 10.0 1.35 5.0 30.0 100.
25 1 53.67 4.80 20.0 2.70 10.0 60.0 200.
40 11⁄2161.0 14.4 60.0 8.10 30.0 180. 600.
m3/H m3/H m3/H
50 2 268.4 24.0 6.0 13.5 3.0 300. 60.
80 3 805.1 72.0 18.0 40.5 9.0 900. 180.
100 4 1073.0 96.0 24.0 53.7 12.0 1200 240.
* Flow Velocity (ft/s) = (Operating GPM x 33.33)/CAL Factor
10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL
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2.0 INSTALLATION
2.1 Inspection
All Model 10D1476 K-MAG magnetic flowmeters are shipped in heavy duty containers. The packag-
ing used for K-MAG protection is certified for air shipment by the Container Testing Laboratory. An
itemized list of all items included in the shipment is attached to the shipping container.
The equipment will generally consist of a magnetic flowmeter and appropriate mounting hardware kit,
and a remote mounted signal converter with a 30 foot (9 m) long interconnection cable. (signal cable
lengths up to 100 feet (30 m) can be supplied, when specified.)
The mounting hardware kit for the standard K-MAG includes:
1) 4 or 8 threaded studs and nuts
2) 2 gaskets
3) appropriate flange adaptor components, if specified.
NOTE
The centering device (see Figure 2-7) or adaptor sleeves (see Fig-
ure 2-8) required for the particular meter installation are supplied by
with all U.S. orders.
When a sanitary K-MAG USDA listed as Accepted Meat and Poultry Equipment is specified, it is
provided with USDA accepted epoxy paint on all exterior surfaces, gaskets certified to FDA/USDA
sanitary requirements and the TRI-CLAMP sanitary adaptors assembled to the meter with all stain-
less steel (studs and nuts) hardware as shown in Figures 2-3 and 2-4.
Inspect all items included in the shipment immediately for indications of damage which may have
occurred during shipment. All damage claims should be reported to the shipping agent involved
before attempting to install or operate the equipment.
The proper use of the items included in the mounting hardware kit and the proper employment of
them during installation is necessary to maintain a valid instrument warranty. (An installation and
warranty tag is furnished with the mounting hardware kit that provides the basic information essential
for proper meter installation.)
Following inspection of the shipment contents, it is suggested that all items be carefully replaced in
the shipping container for transit to the installation site. The use of normal care in the handling and
installation of this equipment will contribute substantially toward satisfactory performance.
10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL
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FIGURE 2-1. OUTLINE DIMENSIONS, SIZES 1/25" THROUGH 1-1/2"
[Modif.]
10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL
2-2

FIGURE 2-2. OUTLINE DIMENSIONS, SIZES 2" THROUGH 4"
[Modif.]
10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL
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2.2 Location
The flowmeter is suitable for either indoor or outdoor installation. When selecting the installation site,
consideration should be given to the ambient and process temperature limits, as stated in Specifica-
tions Section 1.3. The standard meter is rated NEMA 4X, (dust tight and watertight) and will thus
stand rain and hose down. If flooding is a problem, the optional "Accidental Submergence" flowmeter
is suited for applications where occasional submergence to 30 ft H2O/48 h (9 m H2O/48 h) may occur.
Stray electromagnetic and electrostatic fields, low power radio transissions, etc. will have no effect
upon the operating characteristics of the K-MAG magnetic flowmeter system. It is recommended,
however, that the meter not be installed within the immediate proximity of heavy induction equipment
such as pumps, motors, etc.
Outline dimensions of the flowmeter are given in Figures 2-1 through 2-4.
The installation site must be provided with a source of 12 or 24 V dc or 120 V ac, 50/60 Hz (220/240
V ac, 50/60 Hz optional) single phase line power. Power requirements for the particular magnetic
flowmetering system are given on the instrument data tag. The power source must have an external
disconnect and suitable fuse (or circuit breaker) as shown on the applicable interconnection diagram.
System interconnection diagrams are provided in the Instruction Manual supplied with the particular
signal converter.
2.3 Mounting
2.3.1 Meter Orientation
The Model 10D1476 K-MAG magnetic flowmeter may be installed in horizontal, vertical or sloping
pipe runs. However, precautions must be taken to assure that the meter is filled at all times during
measurement. A vertical installation, with the pipe line carrying liquid upwards, assures a filled
hydraulic line under low flow rate conditions and also minimizes wear on the metering tube by
abrasive grit. Horizontal installations should be made with the meter in the lower section of a pipeline
to assure a filled meter condition.
The electronic housing of the meter should be top oriented for horizontal or sloping installations. This
aligns the meter electrodes in a lateral plane, a position that eliminates the possibility of entrained air
acting as an electrode insulator. Electrodes must not be on "top" when the meter is horizontally
mounted.
The magnetic flowmeter must be oriented in accordance with the direction of process flow, as
indicated by the FLOW arrow on the meter data tag. Elbows should be located a minimum of three
pipe diameters upstream from the meter. Control valves should be located on the downstream side
of the meter. Control valves upstream of the meter can create turbulence that result in air pockets
and may effect the meter’s accuracy or cause its output to be noisy. If for some reason the control
valve cannot be located downstream from the meter, a minimum of ten pipe diameters upstream are
required between the meter and the control valve. The requirements for control valves also applies to
pumps. Pipe diameters are measured from the centerline of the meter to the nearest edge of the
device, as shown in Figure 2-5. For higher accuracy requirements, use twice the recommended
number of pipe diameters.
When the process liquid contains abrasive grit, avoid disturbance of the flow profile upstream of the
meter so that the liquid passes smoothly through the meter; elbows and turns can distort the flow
pattern causing uneven wear of the ceramic spool.
10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL
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