MJK MagFlux User manual

1GB MagFlux Manual 0812
Electromagnetic Flow Meter
FW: 841012/842009
Electromagnetic Flow Meter
Installation and User Manual

2GB MagFlux Manual 0812
Electromagnetic Flow Meter
Declaration of Conformity
Jens Kruse
21.11.2006
Electromagnetic Flowmeter
Electromagnetic Flowmeter
Konformitetserklæring
Vi, MJK Automation A/S,
DK-2850 Nærum, påtager os
det fulde ansvar for at produktet
som denne erklæring angår,
er i overensstemmelse med
følgende standard(er) eller andre
normdokument(er).
EN61000-6-3/-4:2001,
EN61000-6-1/-2:1999
efter bestemmelserne i
direktiv
89/336/EEC; 92/31/EEC
Declaration of Conformity
We, MJK Automation A/S,
DK-2850 Nærum, declare under
our sole responsibility that the
product
to which this declaration relates
is in conformity with the following
standard(s) or other normative
document(s).
EN61000-6-3/-4:2001,
EN61000-6-1/-2:1999
following the provisions of
Directive
89/336/EEC; 92/31/EEC
Konformitätserklärung
Wir, MJK Automation A/S,
DK-2850 Nærum, erklären in
alleiniger Verantwortung, dass
das Produkt
auf das sich diese Erklärung
bezieht mit der/den folgenden
Nor me(en) oder normativen
Dokument(en) übereinstimmt.
EN61000-6-3/-4:2001,
EN61000-6-1/-2:1999
Gemäss den Bestimmungen der
Richtlinie
89/336/EEC; 92/31/EEC
Declaration de conformite
Nous, MJK Automation A/S,
DK-2850 Nærum, déclarons
sous notre seule responsabilité
que le produit
auquel se réfère cette déclara-
tion est conforme á la (aux)
norme(s) ou autre(s) document(s)
normatif(s)
EN61000-6-3/-4:2001,
EN61000-6-1/-2:1999
conformément aux dispositions
de Directive
89/336/EEC; 92/31/EEC
Dichiarazione di conformità
Noi, MJK Automation A/S,
DK-2850 Nærum, dichiariamo
sotto la nostra esclusiva respon-
sabilità che l’apparecchio
al quale questa dichiarazione si
riferisce, è conforme alla seg-
uente normativa(e) standard o ad
altri documenti di normativa(e)
EN61000-6-3/-4:2001,
EN61000-6-1/-2:1999
conformemente alla disposizioni
della Direzione
89/336/EEC; 92/31/EEC
Declaración de Conformidad
Nosotros, MJK Automation A/S,
DK-2850 Nærum, declaramos
bajo nuestra única responsabili-
dad que el producto
al cual se refiere esta de-
claración, está en conformidad
con la(s) siguente(e) norma(s) u
otros documentos normativos
EN61000-6-3/-4:2001,
EN61000-6-1/-2:1999
según las disposiciones de la(s)
directiva(s)
89/336/EEC; 92/31/EEC

3
Electromagnetic Flow Meter
FW: 841012/842009
Table of Contents
1. Introduction 7
AboutthisManual ...................................................8
Operating Principles .................................................10
The MagFlux®FlowMeter ............................................11
2. Safety, Repair and Product Identification 13
Safety instructions ..................................................13
PhysicalMounting ..................................................13
Repair ...........................................................13
ProductIdentification................................................14
3. Flow Sensor 15
Minimum conductivity................................................15
Linerselection .....................................................15
Electrode selection ..................................................15
Mounting location...................................................15
Pressureloss......................................................16
Accuracy.........................................................17
Sizing ............................................................17
SizingChart.......................................................18
Pipe System.......................................................19
Cabinet Mounted on the Flow Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Potential Equalization and Grounding ....................................23
Type 7100/7200/7600 in Conductive Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Type 7100/7200/7600 in Non-conductive Pipes............................23
Type 7300/7400 in Conductive Pipes ....................................24
Type 7300/7400 in Non-conductive Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
4. Flow Converter 25
Electrical Mounting ..................................................25
Power Supply......................................................26
Changing the Power Supply Voltage 230/115 V AC . . . . . . . . . . . . . . . . . . . . . . . . . 27
AnalogueOutput ...................................................29
DigitalInput .......................................................30
Local (compact) Flow Sensor ..........................................30
RemoteFlowSensor................................................31
ConverterConnectionBoard-Local ....................................32
ConverterConnectionBoard-Remote ..................................32
5. System Configuration Examples 33
Compact Converter and Display Unit on Flow Sensor. . . . . . . . . . . . . . . . . . . . . . . .33
Remote Converter with Connection Box on Flow Sensor ......................34
WiringSchematic#1 ................................................35
Remote Display and Multiple Converters Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
WiringSchematic#2 ................................................37

4GB MagFlux Manual 0812
Electromagnetic Flow Meter
6. Startup 39
InitialChecks......................................................39
InitialFlowMeasurement .............................................39
Flow Direction Check ................................................39
LanguageSelection.................................................39
DisplayRead-out,oneconnectedunit...................................40
Display Read-out, several connected units ................................41
Display Keys.......................................................41
Initial Setup .......................................................43
7. MagFlux Menus 47
MainMenu.........................................................47
SpecifyMainScreen .................................................48
Factory Settings.....................................................51
Data Logger .......................................................55
Graph Display......................................................57
Password..........................................................58
Set Sensor Name...................................................59
Converter Setup .....................................................61
MinimumFlow.....................................................62
Averaging .........................................................62
Units ............................................................63
mA Output ........................................................63
Flow Forward ......................................................64
FlowReverse......................................................65
Forward & Rev. (12mA=0).............................................65
Forward&rev.(4mA=0)..............................................66
Not in use.........................................................66
Totalizers .........................................................67
Settings and Limits for Resettable Totalizers...............................67
Resettable Totalizers.................................................70
Resettable Forward Totalizer...........................................71
Resettable Reverse Totalizer...........................................71
ResettableSumTotalizer .............................................71
Non-Resettable Totalizers.............................................72
NRForwardTotalizer ................................................72
NRReverseTotalizer ................................................72
NR Sum Totalizer ...................................................72
Batch Counters 1 & 2................................................73
Settings and Limits for Batch Counters ..................................78
High Flow/Low Flow.................................................81
Flow Direction .....................................................83
Empty Pipe........................................................84
Status ...........................................................85
Service Menu ......................................................86

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Electromagnetic Flow Meter
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Display Setup .......................................................95
Language.........................................................96
Set Clock .........................................................97
Modbus..........................................................98
Factory Settings ....................................................99
DisplaySWVersion ................................................100
8. Mechanical Dimensions 101
Standard Flanges - EN-1092-1:2001 - Europe ............................101
Standard Flanges - ANSI B 16.5 - U.S.A. ................................102
Standard Flanges - AS-4087-2004 - Australia . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Standard Flanges - AS-4087-2004 (cont'd)...............................104
Standard Flanges - AS-4087-2004 (cont'd)...............................105
Appendix A. Pop-up and Error Messages 107
Appendix B. MJK-Field Link Software 111
Important Notes! ..................................................111
A. Connect a PC to the Flow Meter ....................................111
B. SaveLogData .................................................113
C. UpgradeDisplayFirmware ........................................113
D. UpgradeConverterFirmware ......................................115
E. Install/Add Languages............................................116
Appendix C. FAQs - Frequently Asked Questions 117
Appendix D. Front Panel Cut-out Drawing 120
Appendix E. Test Certificate 121
Appendix F. Log Files 122
Appendix G. Digital Input/Output Connections 125
Main Menu Overview 126
Converter Setup Menu Overview 128
Service Menu Overview 138
Display Setup Menu Overview 142
Index Index-1

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Electromagnetic Flow Meter
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Electromagnetic Flow Meter
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1. Introduction
Thank you for choosing the MJK MagFlux®electromagnetic flow meter.
We have done our utmost to design and manufacture a flow meter that
satisfies your requirements.
The MagFlux®is suitable for flow measurement in all kinds of conduc-
tive fluids, and it is especially suited for flow measurement of water, waste
water, sludge and other fluids containing particles.
The flow meter is easy to install and put into service. However, read this
manual first to learn about the MagFlux®electromagnetic flow meter and
all its features.
You can always contact your local representative or the MJK hot lines for
advice and guidance:
Europe• Tel.: [phone] E-mail: [email protected]
Denmark• Tel.: [phone] E-mail: [email protected]
Norway• Tel.: [phone] E-mail: [email protected]
Sweden• Tel.: [phone] E-mail: [email protected]
Holland• Tel.: [phone] E-mail: [email protected]
USA• Tel.: [phone] E-mail: [email protected]
Australia• Tel.: [phone] E-mail: [email protected]
Visit our web sites at www.magflux.dk and www.mjk.com to learn more
about MJK Automation, our other products and the people behind them.
MagFlux®is a registered trademark of MJK Automation A/S, Denmark.

8GB MagFlux Manual 0812
Electromagnetic Flow Meter
About this Manual
The manual is divided into a table of contents, eight chapters, seven ap-
pendices, four gatefolds and an index.
1. Introduction
Contains a presentation of the MJK MagFlux®electromagnetic flow
meter, the structure of this manual and the operating principles.
2. Safety, Repair and Product Identification
Provide answers to issues regarding safety, mounting, repair,
restrictions and product identification.
3. Flow Sensor
Describes the physical specifications and installation guidelines for the
flow sensor such as liner and electrode selection, example pipe
systems, sizing chart, etc.
4. Flow Converter
Describes the physical specifications and installation rules for the flow
converter such as power supply, in- and outputs, sensor/converter/
display configurations, etc.
5. System Configuration Examples
Illustrates how MagFlux® sensors, converters and display units can be
interconnected in real-life scenarios.
6. Startup
Describes important checks and basic settings to get started including
the display and keyboard user interface.
7. MagFlux Menus
Contains a comprehensive description of the MagFlux®menus,
options and utilities.
8. Mechanical Dimensions
Lists the flange and sensor dimensions and specifications.
* * * * *
Appendix A. Pop-up Events / Error Messages
Lists possible pop-up messages, explains their meaning and offer
solutions to error conditions.

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Electromagnetic Flow Meter
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Appendix B. MJK-Field Link Software Upgrade
Describes in detail how to utilise the unique and intuitive MJK-Field Link
software program to upload new display and converter firmware
versions.
Appendix C. FAQs - Frequently Asked Questions
Contains answers to questions that are often asked.
Appendix D. Front Panel Cut-out Drawing
A 1:1 scale drawing of the front panel outline and cut-out area for
installation and mounting purposes.
Appendix E. Test Certificate
Shows an example test certificate which is part of MagFlux®
shipments.
Appendix F. Log Files
An example log file illustrates the format and explains the entries.
Appendix G. Digital Input/Output Connections
Illustrates how the digital in- and outputs can be interconnected.
* * * * *
Gatefold 1 Main Menu Overview
Is a continuous presentation of the main menu structure. The size of
this manual does not provide sufficient space for showing the complete
menu structure. Instead, the overview is contained on the attached CD
disc as page Gf-1.
Gatefold 2 Converter Setup Menu Overview
Is a continuous presentation of the converter setup menu structure.
The overview is contained on the attached CD disc as page Gf-2.
Gatefold 3 Service Menu Overview
Is a continuous presentation of the service menu structure.
The overview is contained on the attached CD disc as page Gf-3.
Gatefold 4 Display Setup Menu Overview
Is a continuous presentation of the display setup menu structure.
The overview is contained on the attached CD disc as page Gf-4.

10GB MagFlux Manual 0812
Electromagnetic Flow Meter
Operating Principles
The electromagnetic flow meter is an instrument for measuring the flow
of conductive fluid using Faraday's electromagnetic induction law, and
consequently the fluid must be electrically conductive.
As illustrated below a magnetic field with density B - perpendicular to the
direction of flow - stretches across a fluid flowing within an electrically
isolated pipe.
The magnetic flux will induce a voltage difference (E) that can be measured
between two electrodes arranged perpendicular to the direction of flow
and the magnetic field. The voltage is proportional to the velocity (V) of the
fluid.
➀E = B x D x V x k [Volt] where
E is the voltage that is induced between the two electrodes
B is the magnetic flux density
D is the distance between the two electrodes
V is the fluid velocity
k is a dimensionless constant
The flow of the fluid Q (m3/s) is given by the following formula:
➁Q = πx D2 x V / 4 => V = 4 / (π x D2) where
π : is the constant pi (= 22/7)
D: is the internal diameter
V: is the fluid velocity
The combination of above formulas ➀ and ➁gives the following formula:
E = K x B x D x Q x 4 / (π x D x D) = 4 K x B x Q / (π x D)
Evidently the voltage E is proportional to the actual flow.

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Electromagnetic Flow Meter
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The MagFlux®Flow Meter
Measurement
Electromagnetic flow meters may have either direct current (DC) or alter-
nating current (AC) excitation.
When systems are AC excited, electrostatic and/or electromagnetic noise
may influence the measurements. A DC excited system however, is less
sensitive to noise produced by electromagnetic induction, simply be-
cause the voltage induced over the electrodes will be a DC voltage. The
drawbacks are measurement errors due to electro-chemical polarization
between the electrodes and the fluid.
The MagFlux®electromagnetic flow meters are excited by a 2.5 Hz
square wave and thereby eliminate the drawbacks of both DC and AC
systems.
A microprocessor receives and measures the amplitude of the pulse with a
16-bit resolution, and converts and displays the result on the display unit.
Electrode Cleaning
Electrode cleaning is always in service to maintain clean and accurate
electrodes. The operating principle is a 55 Hz AC voltage superimposed
on the normal 2.5 Hz square wave. This step effectively reduces the risk
of a dirt layer build-up on the electrodes that eventually will deteriorate and
finally isolate electrical contact to the flow media.

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Electromagnetic Flow Meter
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Electromagnetic Flow Meter
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2. Safety, Repair and Product Identification
Safety instructions
1. Read this manual carefully.
2. Pay attention to the environment on the installation site.
3. Wear necessary protective equipment and follow all current safety
regulations.
4. The MagFlux®can invoke a start signal for dangerous machinery.
Always ensure that connected machinery and other equipment are
effectively put out of service (that is to remove the main fuses and lock
main and security switches in off-position) before commencing configu-
ration, fault finding, servicing, maintenance work, etc.
5. WARNING: There is a risk of lethal, electrical shock from "Mains sup-
ply" terminals N and L. Be careful not to touch these terminals while
the MagFlux®is being serviced.
Physical Mounting
The MagFlux®flow converter/flow meter must not be mounted in
explosion hazardous areas!
Repair
Repair must only be made by MJK or by a service representative ap-
proved by MJK.

14GB MagFlux Manual 0812
Electromagnetic Flow Meter
Product Identification
A delivery will usually consist of a MagFlux®converter and a MagFlux®
flow sensor. Check that the item(s) delivered corresponds to the ordered
item(s). The part number and the calibration code are printed on an iden-
tification label sticked onto the flow converter shipping box and on a label
on the flow converter itself. The part number, the serial number, the cali-
bration code and the electrode/lining data for the flow sensor are printed
on a green name plate (see example below).
This calibration code (Cal. code) is unique and provides the MagFlux®
converter with information about flow sensor number, nominal diameter of
the flow sensor and calibration data for the flow sensor.
The current converter firmware requires an 8-character input, but it also
accepts 6 characters plus two "Ok"s. The example above (dw5uq4) would
require that you enter: d w 5 u q 4 "Ok" "Ok", where "Ok" indicates that
you press the "Ok" key without selecting any character. Only small letters
can be entered from the MagFlux® keypad.
If changes are needed to the unique sensor calibration code following
initial setup, this is the calibration code that the "Sensor Calibration Code"
menu must contain (see pages 44 and 86).

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3. Flow Sensor
The following conditions must be satisfied to get the full benefit of the
MagFlux®flow sensor.
Minimum conductivity
The• conductivity of the media must be greater than 5 µS/cm.
Liner selection
Use• Teflon®lining for chemicals and food industries
Use• hard rubber lining for drinking water and waste water
Use• soft rubber lining for water with abrasive particles
Electrode selection
Steel AISI 316TI-1.4571• for general purpose, sewage, water and district
heating systems
Hastelloy• for sea water
Titanium and platinum• for chlorine and other aggressive chemicals
Mounting location
To obtain a stable and accurate flow measurement, it is very important•
that the flow sensor is mounted correctly in the pipe system
There must be no flow fluctuations•
Avoid locations where vacuum can occur; especially for flow sensors•
with Teflon™ linings
Avoid locations with vibrations from for example pumps•
Avoid locations with extensive temperature changes•
Avoid corrosive environments and locations with a great risk of con-•
densation, or consult factory for special builds for these locations
Take care that condensate and water cannot enter the connector box•
on the flow sensor.
There must be sufficient free space around the flow sensor.•
Observe that the correct flow directions are set in the• MagFlux®"Con-
verter Setup" menu and in the "Service Menu" (default flow direction is
"A").

16GB MagFlux Manual 0812
Electromagnetic Flow Meter
The flow directions A or B are clearly shown on the name plate. Default
flow direction is "A".
Pressure loss
The pressure loss can easily be determined, if the nominal pipe diameter is
greater than the MagFlux®flow sensor. See the diagram below:
0.003
Pressure loss graph
The diagram illustrates that decreasing the internal diameter from 100 mm
(DN) to 80 mm (DO) will cause a pressure loss of 0.003 Bar @3 m/s.

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Electromagnetic Flow Meter
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Accuracy
According to the type and size of the flow sensor, the measuring accuracy
will be better than 0.25%, provided that the flow sensor has the correct
dimension.
1
2
3
4
5
[%]
0,20,100,5 21 5 10 m/s
Sizing
The flow sensor should be selected so the flow velocity through the sensor
will be between 0.2 - 10 m/s.
MJK recommends that flow velocities in tubes are kept between 1 - 3 m/s
for reliable and safe operation. See also the dimensioning table below and
the dimensioning chart on the following page.
Min and max flow
DN
Qmin Qmax
DN
Qmin Qmax
DN
Qmin Qmax
0.2 m/s 10 m/s 0.2 m/s 10 m/s 0.2 m/s 10 m/s
[l/h] [l/h] [l/h] [l/h] [m3/h] [m3/h]
3 5.09 254 20 226 11304 65 2,39 119
6 20.4 1018 25 353 17676 80 3,62 181
8 36.2 1810 32 579 28944 100 5,65 283
10 56.5 2827 40 905 45360 125 8,84 442
15 127 6362 50 1414 70560 150 12,7 636
Min and max flow
DN
Qmin Qmax
DN
Qmin Qmax
DN
Qmin Qmax
0.2 m/s 10 m/s 0.2 m/s 10 m/s 0.2 m/s 10 m/s
[m3/h] [m3/h] [m3/h] [m3/h] [m3/h] [m3/h]
200 22.6 1131 450 115 5726 900 458 22902
250 35.3 1767 500 141 7069 1000 565 28274
300 50.9 2545 600 204 10179 1200 814 40715
350 69.3 3464 700 277 13854 The Qmax. is equal to 20 mA
factory preset
400 90.5 4524 800 362 18095

18GB MagFlux Manual 0812
Electromagnetic Flow Meter
Sizing Chart
Example: A MagFlux with an internal diameter of 100 mm can measure
flow rates between approx. 290m3/h and 5.6 m3/h, and the fluid velocity is
1.5 m/s at a flow rate of approx. 42 m3/h.
DN 1200 - 48"
DN 1000 - 40"
DN 900 - 36"
DN 800 - 32"
DN 700 - 28"
DN 600 - 24"
DN 500 - 20"
DN 450 - 18"
DN 400 - 16"
DN 350 - 14"
DN 300 - 12"
DN 250 - 10"
DN 200 - 8"
DN 150 - 6"
DN 125 - 5"
DN 100 - 4"
DN 80 - 3"
DN 65 - 2 1/2"
DN 50 - 2"
DN 40 - 1 1/2"
DN 32 - 1 1/4"
DN 25 - 1"
DN 20 - 3/4"
DN 15 - 1/2"
DN 10 - 3/8"
DN 8 - 5/16"
DN 6 - 1/4"
DN 3 - 1/8"
0,1
0,2
0,3
0,4
0,5
0,6
0,7
0,8
0,9
1
2
3
4
5
6 7
8
9
10
0,2
0,3
0,4
0,5
0,6
0,7
0,8
0,9
1
2
3
4
5
6
7
8
9
10
20
30
40
50
60
70
80
90
0,02
0,01
0,03
0,04
0,05
0,06
0,07
0,08
0,09
0,1
20000
30000
40000
100
200
300
400
500
600
700
800
900
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
1,5
Fluid velocity [m/s]
Flow [m3/h]
Size

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Electromagnetic Flow Meter
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Sizing Chart
Example: A MagFlux with an internal diameter of 100 mm can measure
flow rates between approx. 290m3/h and 5.6 m3/h, and the fluid velocity is
1.5 m/s at a flow rate of approx. 42 m3/h.
Size
Pipe System
1. The flow sensor must be mounted in a location which is free from inter-
fering elements like valves, Ts, bends, pumps, etc. to ensure a laminar
flow without turbulence upstream of the flow sensor. For that reason
the flow sensor must be mounted in a straight pipe at a distance from
interfering elements of minimum 3 x DN upstream and minimum 2 x
DN downstream.
3
2
3
2
3
2
Flow direction
Flow direction
Flow direction
Important: Valves should always be mounted on the downstream side
of the flow sensor!

20GB MagFlux Manual 0812
Electromagnetic Flow Meter
2. If it becomes necessary to use reducers, the inner angle must not
exceed 7.5°.
The minimum length to keep the angle below 7.5° can be checked by
means of the formula below:
L = (D - d) x 7.63
where "D" is the large diameter and "d" the small diameter of the re-
ducer.
Example: If a flow sensor in dimension DN 80 is mounted downstream
of a 100 mm pipe, the reducer must then have a length of minimum
152,6 mm in order to keep the inner angle below 7,5 °.
3. Flange connections must be assembled concentrically on both the up-
stream and the downstream side. Measuring accuracy will be affected
by turbulence in the liquid from poorly made connections.
Important: Gaskets and grounding rings must also be mounted con-
centrically!
4. The flow sensor should always be filled with liquid. For that reason the
flow sensor must not be mounted at the highest point of the pipe sys-
tem or in free outlets, where gravity could empty or partially empty the
pipe.