McCrometer FPI Mag 394L User manual

Model 394L Full Prole Insertion
Electromagnetic Flowmeter
Quick Start Guide
24511-08 Rev. 1.0
February 2011

ii
Copyright © 1997-2011 McCrometer, Inc. All printed material should not be changed or altered without permission
of McCrometer. Any published technical data and instructions are subject to change without notice. Contact your
McCrometer representative for current technical data and instructions. FPI-Mag™ is a trademark of McCrometer, Inc.
www.mccrometer.com
3255 WEST STETSON AVENUE • HEMET, CALIFORNIA 92545 USA
TEL: [phone] • 800-220-2279 • FAX: [phone] Printed In The U.S.A.
Lit. #24511-08 Rev. 1.0/02-11

1
1.2 Safety Warnings
When installing, operating, and maintaining McCrometer equipment where hazards may be present, you must
protect yourself by wearing Personal Protective Equipment (PPE) and be trained to enter conned spaces.
Examples of conned spaces are manholes, pumping stations, pipelines, pits, septic tanks, sewage digesters,
vaults, degreasers, storage tanks, boilers, and furnaces.
You must follow all state and local laws, as well as Occupational Safety and Health Administration (OSHA)
regulations concerning Personal Protective Equipment, conned-space entry, and exposure to bloodborne
pathogens. Specic requirements can be found in the OSHA section of the Code of Federal Regulations: 29 CFR,
1910.132 - 1910.140, Personal Protective Equipment; CFR Title 29, Part 1910.146, Permit-Required Conned-Spaces;
and 29 CFR, 1910.1030, Bloodborne Pathogens.
1.0 Safety
WARNING!
Never enter a conned space without testing the air at the top, middle, and bottom of the space. The
air may be toxic, oxygen decient, or explosive. Do not trust your senses to determine if the air is safe. You
cannot see or smell many toxic gases.
!
WARNING!
Never enter a conned space without the proper safety equipment. You may need a respirator, gas
detector, tripod, lifeline, and other safety equipment.
!
WARNING!
Never enter a conned space without standby/rescue personnel within earshot. Standby/rescue personnel
must know what action to take in case of an emergency.
!
WARNING!
Pressurized pipes should only be hot tapped, cut, or drilled by qualied personnel. If possible,
depressurize and drain the pipe before attempting any installation.
!
WARNING!
Incorrect installation or removal of FPI-Mag meters can result in serious injury or death. Read the
instructions in this manual on the proper procedures carefully.
!
WARNING!
Carefully read all safety warning tags attached to the meter.
!
Introduction:
This FPI Mag Quick Start Guide contains certain important excerps regarding the installation of the sensor and
converter from the Installation, Operation & Maintenance Manual supplied with this meter. It is important to
read the entrie supplied manual before installing either the sensor or converter.
NOTE: The section and Figure numbering remain as they appear in the Manual for easy reference.

2
4.0 Installation
Please read the following information before installing the FPI-Mag sensor.
4.1 Site Selection
While the FPI-Mag is very exible regarding its placement, when installing the sensor at a location with
ow disturbers such as elbows, T-junctions, Y-junctions, and active valves, contact your local McCrometer
representative for a site review and sensor location recommendation.
4.2 Sensor Clearance
The sensor will protrude from the pipe when installed demanding sucient clearance (distance H, in Figure 5
below) from any obstruction. This distance accounts for the length of the sensor, the distance from the outer
pipe wall to the top of the valve plus: 18" is recommended; 12" is the minimum. See App. 3.0 Submittal Sheet
located in the Appendix for the proper calculations for clearance distance.
Figure 5: Sensor Clearance distance
Obstruction
H
4.3 Pipe Valve Installation
Pipe saddle
With Ball Valve
Welded Pipe
Nipple
With Ball Valve
Corporation Stop
Figure 6: Installation Valve Options
WARNING!
Pressurized pipes should only be hot tapped, cut, or drilled by qualied personnel using high quality saddles,
valves and stainless steel nipples. If possible, depressurize the pipe before attempting any installation.
!
Install a 2" (50mm) full port valve or corporation stop with a 2" (50mm) NPT female pipe thread output for the
sensor. Follow any and all installation instructions provided for the valve that you have chosen. The valve or
corporation stop can be installed onto a welded coupling or pipe saddle. See Figure 6. Alternative ball valve or
corporation stop sizes may be used or required. Consult factory for alternative congurations.

3
4.4 Meter Disassembly For Installation
When installing large meters, it can be desirable to remove the compression seal assembly from the rest of the
meter and install it onto the valve separately. The following steps describe the separation of the sensor, top-
plate and retaining rods from the compression seal assembly.
4.4.1 Loosen the bolts on the compression seal relieving the pressure on the compression seal. Do not remove
the bolts.
4.4.2 On the compression seal assembly, remove the locking cotter pins from the bottom of the two retaining
rods under the 3/8" nuts.
4.4.3 Remove the 3/8" nuts from the retaining rods.
4.4.4 Slide the sensor out of the compression seal. The retaining rods will also slide out of the compression seal
assembly. Carefully set the sensor and attached hardware to the side.
4.4.5 At this point the compression seal assembly can be installed onto the valve.
Figure 7: Sensor Installation
Compression
Seal Threads
Bottom Plate
Compression
Seal Assembly
4.5 Compression Seal Assembly Installation
The sensor assembly uses a compression seal, which keeps the sensor watertight when the pipe is under
pressure. Care must be taken when installing the sensor, to avoid leaks.
4.5.1 Visually inspect all elements of the installation to insure they are structurally sound and of high quality
materials, including all welds, couplings and nipples. To prevent future corrosion, nipples should be high quality
stainless steel.
4.5.2 Put a generous amount of the pipe sealant (supplied with the sensor) on the compression seal threads.
(Teon tape may also be used.) NOTE: if pipe sealant gets on the sensor electrodes the velocity signal may be
lost.
4.5.3 Place the compression seal threads over the pipe valve. Turn the entire sensor assembly clockwise to secure
the assembly to the valve.
4.5.4 The seal is secure when a large amount of force is required to turn the assembly. Line up the arrow (on the
top plate) with the direction of the ow. The sides of the bottom plate should be parallel with the pipe.

4
4.6 Meter Re-assembly After Compression Seal Assembly Installation
4.6.1 Apply liquid soap, such as Simple Green, to the interior surface of the seal gland. This will act as a
lubricant to facilitate the insertion of the sensor and ensure its proper axial loading. Insert the sensor into the
compression seal in the bottom plate while inserting the two retaining rods into their respective holes in the
bottom plate and secure with 3/8" nuts. Insure the two nuts above and below the compression seal assembly
are suciently tightened to prevent the threaded rod from rotating.
4.6.2 Insert the locking cotter pins through the small holes in the bottom of the retaining rods, just below the
3/8" nuts.
Figure 8: Sensor Installation
4.7 Inserting The Sensor
Figure 9: Sensor vibration
The sensor can be installed while the line is under owing conditions. The line water
velocity should be as low as possible to prevent sensor vibration during the insertion
process. The velocity must be under 5 ft./sec.
If the meter was disassembled to assist in the installation of the compression seal assembly on to the valve (Section
4.4) it is important to insure that the meter is properly reassembled with both retaining rods completely installed
with the 3/8" nuts properly tightened.
4.7.1 Insure the two compression seal bolts are hand tightened.
4.7.2 Barely crack open the valve and tighten compression seal bolts as required to minimize leaks. A towel draped
around the compression seal can reduce spray if necessary.
4.7.3 Open the valve completely. Failure to open the valve completely will cause the valve to scrape the sensor
during insertions and may result in permanent damage to the sensor.
WARNING!
The compression seal/sensor assembly may be under pressure.
Serious injury may result if proper procedures are not followed. Do
not attempt to install the sensor without the retaining rods fully
assembled.
!

5
Figure 10: Captive Nuts
NOTE
If the short retaining rods are not used (see Section 4.11), run a 3/8" nut down against each captive nut to
prevent the captive nut from rotating.
4.7.4 Insert the sensor into the pipe by simultaneously rotating the two captive nuts on the top plate clockwise
with the two ratchet wrenches provided until the foot of the sensor reaches the far wall of the pipe and the load
spring is compressed. See Section 4.7.5. It is recommended that the sensor insertion tool (p/n 75031) be used to
rotate the captive nuts to insure the top plate compresses evenly. See Section 4.8.
4.7.5 A load is now applied at the top of the sensor forcing the
bottom of the sensor to seat against the far wall. This keeps the
sensor rmly in place against the far wall of the pipe. The amount
of load is indicated by the three lines and set screw at the top of
the sensor. See Figure 11. The bottom line indicates a 300-lb. load.
Recommended sensor loads are 300 lbs. or less for low pressure
plastic pipes and 450 lbs. for low pressure metal pipes.
For applications other than low pressure the sensor load should
be increased. Follow the instructions below until the set screw
is between the top and middle lines. Consult factory for the
appropriate loading for your application.
4.7.6 Rotate the two captive nuts on the top plate until the
proper load is indicated If using the Insertion Tool, rotate the two
captive nuts using only the low gear shaft until the proper load is
indicated. DO NOT use the high gears on the insertion tool as this
may create too much load too fast and damage the sensor or the
pipe.
4.7.7 Tighten the compression seal bolts again. The bolts should be tightened down rmly.
IMPORTANT
If the captive nuts are not tightened simultaneously, the top plate will become crooked and cause the
sensor to be inserted at an angle and may cause permanent damage to the sensor.
i
i
Captive Nuts
Rotate captive
nuts clockwise
simultaneously to
insert sensor.
Figure 11: Sensor Load Indicators

6
Figure 12: Insertion Tool
4.8 Sensor Insertion Tool
McCrometer recommends using a sensor insertion tool (P/N 75031) to
help with inserting the sensor and to avoid any damage to the sensor.
Place the proling insertion tool over the captive nuts and lock it into
place with spring locks located on the bottom of the tool. Using the
provided wrench rotate the high gear shaft clockwise until the bottom of
the sensor reaches the far wall of the pipe. The low gear shaft is used to
apply pressure to the sensor once the sensor has reached the far wall of
the pipe. See Section 4.7.5.
4.9 Installing The Short Retaining Rods
After the sensor has been inserted and the load adjusted, shorter retaining rods can be installed and the longer
ones removed. This will make the sensor assembly more compact.
Figure 13: Short Retaining Rods Installation on 2" Meter
4.9.1. Secure the short retaining rods to the compression seal assembly following the instructions at Section 4.6.
4.9.2. Secure the short retaining rods to the top plate with one 3/8" nut per rod.
4.9.3. Remove the long retaining rods.
4.9.4. Check and adjust the "Sensor Load" as necessary. See section 4.7.5.
4.9.5. Secure the 3/8” nuts on the top plate by running a second jam nut down and tightening it against the rst
nut.
IMPORTANT
The long retaining rods are matched to each sensor and are required for removal of the sensor. It is
important to safely store the long retaining rods and label them with the meter serial number.
i
Locking
Cotter Pin
3/8" Nuts
Short Retaining
Rods
Captive
Nut

7
Figure 17: Cable Cover
6.3 Pulling Sensor Cable Through Electrical Conduit
It is very important to protect the end of the sensor cable when pulling it through a conduit. Water can
accumulate in low portions of conduit. Always use the factory supplied cable plug, or similar method, to seal
the end of the cable against water when pulling the cable through conduit. See Figure 17. This will insure proper
operation of the meter.
Pulling The Sensor Cable:
1. Tie a rope or cable-snake securely around the middle of the cable plug.
2. Carefully pull the rope or snake until the sensor cable end clears the conduit.
3. Bring the cable end to the converter location. If necessary, secure the cable so that it does
not fall back through the conduit.
4. Remove the cable plug by pulling the rip–wire. The cable plug will tear o (discard the plug).
Caution: Do not cut the cable cover o. Doing so may damage the sensor cable and adversely eect the
calibration of the meter.
i
Sensor Cable
Cable Cover
Secure rope or snake to this
area of the cable cover
Rip Wire
6.2 Installing Cables To Converter And Service Loop
Conduit of any kind CANNOT be attached directly to the electronics enclosure. Attaching conduit directly to the
enclosure will introduce dangerous gasses and moisture into the enclosure creating a dangerous condition, and
will remove the enclosure's IP67 rating. Attaching conduit to the enclosure or altering the enclosure in any
way will void the warranty.
Any cable running through a conduit must exit the conduit and have a minimum of an 8" service loop before
entering the electronics enclosure through the cable glands. This allows the electronics enclosure to be rotated
and the rear panel to be accessed. If electrically bonding (grounding) the enclosure to metallic conduit or
raceways, secure a lead wire to the enclosures back panel screw and attach the lead to a listed and approved
conduit grounding bushing. See Figure 16. To insure IP67 rating use only round cable 0.125" to 0.375" in diameter.
WARNING: Do not connect any form of conduit directly to the converter enclosure. Doing so will allow
moisture and potentially dangerous gasses to enter directly into the converter. Attaching any conduit to the
enclosure, or altering the enclosure in any way will void the warranty.
!
Figure 16: Cable Installation, Service Loop And Bonding To Metallic Conduit
Grounding Lead
Sensor Cable
(Showing 8”
Service Loop)
Power Cable
Conduit Grounding
Bushing
Enclosure Front Enclosure Back
Enclosure
Backplate
screw
IMPORTANT: All cables must have a minimum 8" service loop.

8
All electrical cables enter the unit through compression ttings located on the side of the converter. Ensure that
all unused ttings are plugged so the case remains sealed.
6.5 Terminal Board
All connections are made on the terminal board. To access the terminal board, loosen the four screws on the
back of the converter to remove the rear cover.
6.6 Sensor Cable
The terminals for the bi-directional sensor cable connection are
numbers 12, 13 on Terminal Block M1 and C, e1F, e2F, e2R and e1R on
the electrode terminal block. Connect the sensor cable wires using
the color code table below. NOTE: the terminal blocks unplug from
the circuit board for easy connection.
6.4 Electrical Cable Connections
Figure 19: Terminal Block M1
Assignments
CAUTION
Always disconnect the AC power cord before attempting any electrical connections.
Figure 18: Terminal Board Descriptions
Figure 20: Sensor Cable Connections
INPUTS
+ -
RS485
B A
4-20mA
+ -
123 4 5 7
68910
11 12 13 14 15 16 17 18 19 20
COILS
+
24V
C E
OUT1
SH C E
OUT2
-
24V
i
Terminal Wire Color Connected To
#12 Yellow Coil
#13 Red Coil
C Black Ground electrodes
e1F Blue Forward Electrodes 1
e2F Pink Forward electrodes 2
e2R Pink (In
shrink tube)
Reverse electrodes 2
e1R Blue (In
shrink tube)
Reverse electrodes 1
Dip switch for block
levels enabling
Signaling LED
IF2 socket
Power Supply
C e1F e2F e2R e1R
Blue Forward Pink Forward
Yellow Red
Shrink
Tube
On
Reverse
Electrode
Wires
Cable
Jacket
Blue Reverse
Pink Reverse
Black Common
C e1F e2F e2R e1R
Shrink
Tube
11 12 13 14 15 16 17 18 19 20

9
6.7 4-20mA Hook-Up
Isolated 4-20mA current loops are used to output ow data to external devices. Maximum load impedance is
1,000Ω, and the maximum voltage without load is 27VDC. The converter has the capability to detect a loss of
load on this output. To disable this function set the value “mA Val. Fault” (Section: Main Menu, Sec.. 4.7) under
the ALARMS menu to zero. A graphical example of the usage of the current loop with external device is shown
below:
If the external device requires a voltage input, a precision resistor placed across the input terminals of the
external device will change the current to voltage. Calculate the required resistor using Ohm’s law (V = I x R). For
example, a 250Ω resistor will provide an input voltage of one to ve volts with the transmitter range being set
from 4mA to 20mA.
+
-
Common
Figure 21: 4-20mA Hook-Up
6.8 Converter Power Hook-Up
WARNING!! Hazardous supply voltage can shock, burn, or cause death.
The power supply line must be equipped with external surge protection for current overload (fuse or circuit
breaker with limiting capacity not greater than 10A). It must be easily accessible for the operator and clearly
identied.
Power connection is made using the power terminal block on the upper right side of the terminal board. NOTE:
the terminal block uplugs from the circuit board for easy connection. Connect earth ground to the protective
grounding terminal before making other connections. The power supply of a standard converter is 90-265VAC,
44-66Hz at maximum 20W. DC converter is available as an option.
Figure 25: Power Supply Terminal Block
L N
Neutral Wire
Typically A
White Wire
Ground Wire
Typically A
Green Wire
Line Wire
Typically A
Black Wire
!
The default setting for the 394L
4-20mA output is split
4-12mA = reverse ow
12mA = zero ow
12-20mA = forward ow

10
7.0 Converter Start-Up
Before starting up the converter please verify the following:
• Power supply voltage must correspond to that specied on the name plate
• Electric connections must be wired as described in this manual
• Ground connections must be properly installed
When the instrument is powered and exhibits dierent operating conditions than those at the last shutdown, it
initiates a verication cycle of the converter. During the verication cycle the converter displays an incrementing
diagnostic number from 0 through 90. When the diagnostic is complete an error number will be displayed
referencing the chart at the back of this manual. A text message will also be displayed on the alarm screen (to
view alarms, press the UP arrow key from the main display screen).
7.1 Menu Navigation
To navigate through the menus on the converter, the keys on the keypad use the following conventions:
SHORT PRESSING (< 1 SECOND):
It moves the cursor up to the previous subject on the menu
It increases the numeric gure of the parameter highlighted by the cursor
Batch start/stop (when enabled)
LONG PRESSING (> 1 SECOND):
It moves the cursor down to the next subject on the menu
It decreases the numeric gure of the parameter highlighted by the cursor
UP ARROW KEY (for moving cursor up or down)
SHORT PRESSING (< 1 SECOND):
It moves the cursor to the right on the input eld
It moves the cursor to the following subject of the menu
It changes the display of the process data
LONG PRESSING (> 1 SECOND):
It moves the cursor to the left on the input eld
It moves the cursor to the previous subject on the menu
RIGHT ARROW KEY (for moving cursor right or left)
RIGHT COMMAND KEY (for changing settings)
SHORT PRESSING (< 1 SECOND):
It opens the main menu for the instrument conguration
It enters/leaves the selected function
It cancels the selected function under progress
LONG PRESSING (> 1 SECOND):
It conrms the selected function
It leaves the current menu
It enables the totalizer reset request (when enabled)
Key: Function:

11
NOTES:

Copyright © 1997-2011 McCrometer, Inc. All printed material should not be changed or altered without permission of McCrometer.
Any published technical data and instructions are subject to change without notice. Contact your McCrometer representative for
current technical data and instructions. FPI-Mag™ is a trademark of McCrometer, Inc.
www.mccrometer.com
3255 WEST STETSON AVENUE • HEMET, CALIFORNIA 92545 USA
TEL: [phone] • 800-220-2279 • FAX: [phone] Printed In The U.S.A. Lit. #24511-08 Rev. 1.0/02-11
OTHER McCROMETER PRODUCTS INCLUDE:
Magnetic Flowmeters
Magnetic Flowmeters
Magnetic Flowmeters
Propeller Flowmeters
Remote Telemetry System
Propeller Flowmeters
Differential Pressure Flowmeters
Differential Pressure Flowmeters
Differential Pressure Flowmeters
Represented By: