Aplisens PEM-1000ALW User manual

USER’S MANUAL
ELECTROMAGNETIC FLOWMETER
PEM-1000
EN.IO.PEM.1000
JUNE 2021
APLISENS S.A., 03-192 Warsaw, Morelowa 7 St.
tel. [phone]; fax [phone]
www.aplisens.com, e-mail: [e-mail]
Revision 02.A.004

Symbols used
Symbol
Description
Warning to proceed strictly in accordance with the information contained in the doc-
umentation in order to ensure the safety and full functionality of the device.
Information particularly useful during installation and operation of the device.
Information on disposal of used equipment.
BASIC REQUIREMENTS AND SAFE USE
The manufacturer will not be liable for damage resulting from incorrect installation,
failure to maintain a suitable technical condition of the device or use of the device
other than for its intended purpose.
Installation should be carried out by qualified staff having the required authoriza-
tions to install electrical and I&C equipment. The installer is responsible for perform-
ing the installation in accordance with manual as well as with the electromagnetic
compatibility and safety regulations and standards applicable to the type of installa-
tion.
In systems with I&C equipment, in case of leakage, there is a danger to staff due to
the medium under pressure. All safety and protection requirements must be ob-
served during installation, operation and inspections.
If a malfunction occurs, the device should be disconnected and handed over to the
manufacturer for repair.
In order to minimize the risk of malfunction and associated risks to staff, the device
is not to be installed or used in particularly unfavourable conditions, where the fol-
lowing hazards occur:
−possible mechanical impacts, excessive shocks and vibration;
−excessive temperature fluctuation;
−water vapour condensation, dusting, icing.
Changes made to the manufacturing of products may be introduced before the paper version of the
manual is updated. The up-to-date manuals are available on the manufacturer’s website:
www.aplisens.com.

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Revision 02.A.004/2021.06 3
TABLE OF CONTENTS
1. INTRODUCTION ......................................................................................... 5
1.1. Trademarks ...........................................................................................................................5
2. SAFETY ...................................................................................................... 5
3. TRANSPORT AND STORAGE ................................................................... 6
3.1. Delivery check .......................................................................................................................6
3.2. Transport...............................................................................................................................6
3.3. Storage..................................................................................................................................6
4. GUARANTEE.............................................................................................. 6
5. IDENTIFICATION........................................................................................ 7
5.1. Manufacturer’s address .........................................................................................................7
5.2. Flowmeter identification.........................................................................................................7
5.3. CE mark, declaration of conformity........................................................................................8
6. INSTALLATION .......................................................................................... 9
6.1. General recommendations.....................................................................................................9
6.2. Recommended installation methods for flow sensor ..............................................................9
6.3. Installation of the PEM-1000 flowmeter................................................................................11
7. ELECTRICAL CONNECTION ................................................................... 13
7.1.1. Connecting the sensor signal cable..............................................................................14
7.2. Grounding............................................................................................................................16
Marking of the connection point of the functional earth of the flowmeter........................................16
7.2.1. Connecting of the transmitter with the option of using local HART communication.......16
7.2.2. Functional grounding....................................................................................................17
8. START-UP ................................................................................................ 19
9. TECHNICAL PARAMETER....................................................................... 19
9.1. Protection class ...................................................................................................................19
9.2. Technical specification.........................................................................................................19
9.3. Technical specification.........................................................................................................20
9.4. Metrological parameters ......................................................................................................20
9.5. Table of volumetric flows calculated for the characteristic flow velocities of the medium for
versions with flanges according to DIN................................................................................21
9.5.1. Selection of flowmeter diameter and measuring range.................................................22
10.MAINTANANCE........................................................................................ 24
10.1. Periodic inspections.............................................................................................................24
10.2. Non-periodic inspections......................................................................................................24
10.3. Cleaning/Washing................................................................................................................24
11.TROUBLESHOTING................................................................................. 25
11.1. Measurement board error E_FE_xx.....................................................................................25
11.2. Sensor error E_SENS_xx ....................................................................................................26
12.SCRAPING, DISPOSAL............................................................................ 26
13.HISTORY OF REVISIONS......................................................................... 26
APPENDIX A –Configuration Local MENU Settings................................... 27
APPENDIX B - Structure of the local MENU ................................................ 35

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LIST OF DRAWINGS
Figure 1. Recommended examples of sensor installation....................................................................9
Figure 2. Examples of incorrect sensor installation on the site and suggested solutions. ..................10
Figure 3. Installation of the PEM-1000 flowmeter - examples............................................................11
Figure 4. Examples of installation of the flowmeter transmitter in the PEM-1000NW version on a pipe
and on the wall...................................................................................................................................12
Figure 5. Electrical wiring from the PEM-1000 transmitter.................................................................13
Figure 6. View of electrical terminals of the PEM-1000 flowmeter.....................................................13
Figure 7. Marking the leads of the sensor cable cores.......................................................................15
Figure 8. Connection pins of the sensor cable plug...........................................................................15
Figure 9. Location and method of connecting the protective earth to the transmitter housing............16
Figure 10. Proper preparation of the power cable..............................................................................16
Figure 11. Example of a functional earthing connection for a metal pipeline and for an insulated
pipeline using earthing rings. .............................................................................................................17
Figure 12.The way of connecting the functional ground to the transmitter housing...........................17
Figure 13.The method of connecting functional ground to the sensor housing.................................18
Figure 14. Graph of correct functional grounding of the PEM-1000 flowmeter...................................18
Figure 15. Recommended flow values of the PEM-1000 flowmeter...................................................22
Figure 16. The measuring range of the flowmeter is determined by the Qmax parameter.................23
LIST OF TABLES
Table 1. Symbols appearing on the flowmeter's nameplate.................................................................7
Table 2. Symbols appearing on the sensor's nameplate......................................................................8
Table 3. Designation of connection terminals of the PEM-1000 flowmeter.........................................14
Table 4. Connection pins of the sensor cable plug.............................................................................15
Table 5. Technical data of the sensor and transmitter. ......................................................................19
Table 6. Flow values for the PEM-1000 flowmeter.............................................................................20
Table 7. Volumetric flow as a function of the linear velocity of the medium........................................21
Table 8. Flow values corresponding to a speed of 1 m/s. ..................................................................22
Table 9.Error descriptions of the PEM-1000 flowmeter and their possible solutions..........................25

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1. INTRODUCTION
The subject of manual are electromagnetic flowmeters in two versions:
−A compact version designated PEM-1000ALW - with transmitter placed directly on the meas-
uring sensor;
−A remote version designated PEM-1000NW - with transmitter connected via cable and placed
up to 50 m from measuring sensor.
The manual contains data, guidelines and recommendations concerning installing and operating, as
well as procedure in the event of a failure.
The description of device configuration can be found in the EN.IK.PEM-1000 configura-
tion manual, and the Modbus communication is described in the IM.PEM-1000(ENG).
They are available on the manufacturer's website www.aplisens.com
1.1. Trademarks
Modbus®is a service registered and managed by SCHNEIDER AUTOMATION, INC..
2. SAFETY
−The installation and start-up of the device and any activities related to operation shall be
carried out after thorough examination of the contents of user’s manual and the instruc-
tions related thereto;
−installation and maintenance should be carried out by qualified staff having the required
authorizations to install electrical and measuring devices;
−the device shall be used according to its intended purpose in line with the permissible
parameters specified on the nameplate (➔Flowmeter identification);
−the protection elements used by the manufacturer to ensure transmitter safety may be
less effective if the device is operated in a manner not consistent with its intended pur-
pose;
−before installing or disassembling the device, it is absolutely necessary to disconnect it
from the power source;
−no repairs or alterations to the transmitter electronic system are permitted. Assessment
of damages and possible repair may only be performed by the manufacturer or author-
ized representative;
−do not use instruments if damaged. In case of malfunction, the device must be put out of
operation;

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3. TRANSPORT AND STORAGE
3.1. Delivery check
After receiving the delivery of the equipment, it is necessary to:
−make sure that the packaging and its contents were not damaged during transport;
−check the completeness and correctness of the received order, and make sure no parts are
missing.
3.2. Transport
Transport of flowmeters shall be carried out with the use of covered means of transport, in original
packages. The packaging shall be protected against movement and direct impact of atmospheric fac-
tors.
3.3. Storage
Flowmeters shall be stored in a factory packaging, in a room without vapours and aggressive sub-
stances, protected against mechanical impact.
Allowable range of ambient and storage parameters:
Allowable range of ambient/storage temperature
-20 … 60ºC (-4 … 140°F)
Relative humidity
to 80%
Surrounding atmosphere
No aggressive ingredients
Height above sea level
to 2000 m
The permissible ambient and device operating parameters must not be exceeded. Exceeding
them may result in an increase in measurement errors.
4. GUARANTEE
General terms and conditions of guarantee are available on the manufacturer's website:
www.aplisens.com/ogolne_warunki_gwarancji
The guarantee shall be repealed if the device is used against its intended use, failure to
comply with user’s manual or interference with the structure of the device.

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5. IDENTIFICATION
5.1. Manufacturer’s address
APLISENS S.A.
03-192 Warsaw
Morelowa 7 St.
Poland
5.2. Flowmeter identification
Table 1. Symbols appearing on the flowmeter's nameplate.
Logo and name of manufacturer.
CE mark.
Manufacturer’s address.
Flowmeter type .
Min/Max of flow value.
Supply voltage values.
Output signal.
Serial number of flowmeter.
Serial number of sensor.
Year of production.
IP protection rating.
Note about the obligation to read the manual.
Information on dealing with used equipment.

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Table 2. Symbols appearing on the sensor's nameplate.
Logo and name of manufacturer.
CE mark.
Sensor type.
Serial number of sensor.
Year of production of the sensor.
Sensor lining.
Electrode material.
IP protection rating.
,
Value of calibration coefficient A and B.
Information on dealing with used equipment.
Note about obligation to read the manual.
Direction flow of medium.
Manufacturer’s address.
5.3. CE mark, declaration of conformity
The device has been designed to meet the highest safety standards, has been tested and has left the
factory in a condition that is safe for operation. The device complies with the applicable standards and
regulations listed in the EU Declaration of Conformity and has CE marking on nameplate.

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6. INSTALLATION
6.1. General recommendations
-It is recommended that the flow direction is in the direction of the arrow on the sensor,
the transducer is also factory set to work in this direction. The flow in the opposite direction to
the arrow is shown as a negative value. If it is necessary to mount the sensor upside down,
please contact the manufacturer.
-Before installation, check if there is enough space next to the flange for installing the flow
meter with the use of bolts and nuts.
-During the measurement, the entire space inside the sensor should be filled with the meas-
ured liquid.
-Fix the pipework on both sides of the flowmeter to avoid vibration and sag in the pipework from
affecting the measurement.
-If the flowmeter is installed in a pipeline with a larger ID, use a reducer that ensures axial fixa-
tion without increasing stress on the sensor pipes and flanges. Remember to keep straight
sections in front of and behind the sensor.
-During installation the straight sections should be of nominal diameter of the sensor (DN) with
lengths of at least 5DN before and 3DN after the sensor.
-When installing the sensor on an insulated pipe (e.g. glass, plastics etc.) please insulate
the system with earthing rings connected with ground terminal of the sensor ➔Figure 11.
-Conductive connection between ground (enclosure) of the sensor and liquid is necessary
for correct measurements.
-During assembly it is essential to install a seal between the flanges of the sensor and the
piping. When using grounding rings, seal use rings on both sides.
-Do not use gaskets made of hard materials as they may damage the Teflon lining or, in the
case of rubber lining, fail to ensure a sufficient tightness of the installation.
-Make sure that no sealing element enters the lumen of the pipeline as this may introduce
turbulence into the flow and disrupt the operation of the flowmeter.
6.2. Recommended installation methods for flow sensor
Figure 1. Recommended examples of sensor installation.

EN.IO.PEM.1000
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To avoid metrological errors caused by air bubbles or damage floor covering, follow the recommenda-
tions below:
-during installation, properly position the sensor, tighten the flange bolts simultaneously on both
sides;
- it is recommended that the flowmeter is installed so that the electrode axis is as horizontal as
possible, in accordance with the examples ➔Figure 3. Installation of the PEM-1000 flowme-
ter - examples.
- Teflon lining requires special care during handling and assembly. During installation (opera-
tion), avoid excessive under pressure in the pipeline. Do not damage liner leads to the outer
flange surfaces on both sides of the sensor. Some sensors are delivered from the manufactur-
er with special covers that prevent the deformation of the Teflon lining. Covers should be re-
moved immediately before installation, before placing between the counter flanges;
- ensure that no seal element enters the lumen of the pipeline, as this may introduce turbulence
into the flow and disturb the flowmeter.
A
B
Figure 2. Examples of incorrect sensor installation on the site and suggested solutions.
The figure shows the two most common cases of incorrect installation of a flowmeter sensor on
a facility.
Case A shows incorrect installation of the pump (behind the sensor). This type of mounting can cause
This type of mounting can cause distortion of the flow values and also expose the electrodes, which
can result in an error of empty pipe detection. In extreme cases the vacuum generated by the pump
can damage the sensor lining.
Case B shows the sensor mounted at the end of the pipeline. This way of mounting may cause This
type of mounting can cause the electrodes to be exposed, which will result in a distortion of the flow,
as well as the ingress of air and drying up of the medium on the inner walls of the sensor. In order to
avoid problems with the functioning of the device, it is recommended to use a siphon as shown in the
picture.