Xylem MJK MagFlux Series User manual

Manual
EN 3.05 Version 2102
MagFlux® Series
ELECTROMAGNETIC FLOWMETER

MagFlux® Series
EN 3.05 Version 2102
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Your notes:

MagFlux® Series
EN 3.05 Version 2102
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Table of Contents
MJK declaration of conformity..................................................................................................8
Introduction.................................................................................................................................9
Introduction - MagFlux® Q ....................................................................................................9
Operating principles ..............................................................................................................9
The MagFlux® Flow Meter.................................................................................................. 10
Safety, repair and product identification...............................................................................11
Safety instructions................................................................................................................ 11
Physical mounting................................................................................................................ 12
Repair .................................................................................................................................... 12
MJK product identification ................................................................................................. 12
Flow sensor................................................................................................................................14
Minimum conductivity......................................................................................................... 14
Liner selection ...................................................................................................................... 14
Liner selection, cont. ........................................................................................................... 14
Electrode selection.............................................................................................................. 14
Mounting location ............................................................................................................... 14
Pressure loss......................................................................................................................... 16
Accuracy ............................................................................................................................... 17
MJK sizing............................................................................................................................. 17
Sizing chart ........................................................................................................................... 20
Pipe system........................................................................................................................... 23
Pipe system - MagFlux Q special conditions................................................................ 28
Cabinet mounted on the flow sensor................................................................................ 28
Potential equalization and grounding .............................................................................. 29
Type 7100/7200/8200 in conductive pipes ................................................................. 29
MagFlux® in conductive pipes, MagFlux® Q ...........................................................29
Type 7100/7200/8200 in non-conductive pipes......................................................... 30
MagFlux® in non-conductive pipes, MagFlux® Q ...................................................30
Type 7300 in conductive pipes...................................................................................... 31
Type 7300 in non-conductive pipes.............................................................................. 31
Cathodic protection ............................................................................................................ 32
Type 7100/7200 in conductive pipes ........................................................................... 32
Type 7100/7200 in non-conductive pipes ................................................................... 32
Flow converter ..........................................................................................................................34
Electrical mounting.............................................................................................................. 34
Power supply........................................................................................................................ 35
Change power supply voltage 230/115 V AC ................................................................. 36
Analogue output.................................................................................................................. 39
Digital outputs...................................................................................................................... 39
Digital input.......................................................................................................................... 40
Local (compact) flow sensor............................................................................................... 41
Remote flow sensor ............................................................................................................. 41
Converter connection board - local .................................................................................. 43

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Connection board - remotely mounted converter.......................................................... 44
System configuration examples..............................................................................................45
Compact converter and display unit on flow sensor....................................................... 45
Remote converter with connection box on flow sensor ................................................. 46
Wiring schematic #1............................................................................................................ 47
Remote display and multiple converters wiring .............................................................. 48
Wiring schematic #2............................................................................................................ 48
Startup........................................................................................................................................50
Initial checks ......................................................................................................................... 50
Initial flow measurement..................................................................................................... 50
Flow direction check ........................................................................................................... 50
Language selection ............................................................................................................. 51
Display read-out, one connected unit .............................................................................. 51
Display read-out, several connected units ....................................................................... 52
Display keys.......................................................................................................................... 53
Initial setup ........................................................................................................................... 54
MagFlux® menus ......................................................................................................................57
Main menu............................................................................................................................ 57
Specify main screen............................................................................................................. 58
Factory settings.................................................................................................................... 62
Data logger........................................................................................................................... 66
Graph display................................................................................................................... 68
Password............................................................................................................................... 69
Set sensor name................................................................................................................... 70
Converter setup ................................................................................................................... 73
Minimum flow...................................................................................................................74
Averaging ......................................................................................................................... 76
Units................................................................................................................................... 77
mA output......................................................................................................................... 77
Flow forward.................................................................................................................78
Flow reverse .................................................................................................................79
Forward & rev. (12mA=0) ...........................................................................................80
Forward & rev. (4mA=0) .............................................................................................81
Not in use......................................................................................................................82
Totalizers........................................................................................................................... 82
Settings and limits for resettable totalizers ..............................................................83
Resettable totalizers ....................................................................................................86
Batch counters 1 & 2 ....................................................................................................... 89
Settings and limits for batch counters.......................................................................94
High flow/low flow...........................................................................................................97
Flow direction................................................................................................................... 99
Empty pipe .....................................................................................................................101
24h flow...........................................................................................................................102
Status...............................................................................................................................102
Service menu..................................................................................................................105
Sersor calibration code............................................................................................ 105

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Converter software ver............................................................................................. 106
Product info ............................................................................................................... 107
Reset counter time.................................................................................................... 107
Internal meas. & cal. ................................................................................................. 108
Minimum velocity...................................................................................................... 108
Calibrate mA ............................................................................................................. 109
Test velocity............................................................................................................... 111
Freeze coil ................................................................................................................. 112
Read eventlog ........................................................................................................... 113
Back on stock ............................................................................................................ 113
Popup on/off ............................................................................................................. 114
Zero point calibration............................................................................................... 114
Verification................................................................................................................. 116
Display setup...................................................................................................................... 116
MJK communication modules documentation..........................................................117
Language........................................................................................................................117
Set clock..........................................................................................................................119
Modbus...........................................................................................................................119
Add Device................................................................................................................ 120
Change Device Address.......................................................................................... 121
Remove Device ......................................................................................................... 122
Change Display ID No.............................................................................................. 123
Set No. of Retries ...................................................................................................... 123
Change Modbus speed ........................................................................................... 124
Factory setting setup.....................................................................................................124
Display SW version ........................................................................................................125
Mechanical dimensions ........................................................................................................ 126
MJK standard flanges - EN-1092-1_2001 - Europe....................................................... 126
MagFlux Q sensor sizes and torque............................................................................128
MJK standard flanges - ANSI B 16.5 - U.S.A................................................................... 129
MJK standard flanges - AS-4087-2004 - Australia......................................................... 132
MJK standard flanges - AS-4087-2004 (continued #1)................................................. 134
MJK standard flanges - AS-4087-2004 (continued #2)................................................. 136
Flygt standard flanges - EN-1092-1_2001 - Europe...................................................... 138
Appendix A. Pop-up and error messages.......................................................................... 141
Appendix B. MJK Field Link™ software.............................................................................. 144
System Requirements MJK Field Link™ ......................................................................... 144
Download MJK Field Link™ and connect a PC to the MagFlux® flow meter ............ 144
Save log data...................................................................................................................... 146
Upgrade display firmware. ............................................................................................... 146
Upgrade converter firmware............................................................................................ 147
Install/Add languages ....................................................................................................... 148
Appendix C. FAQs................................................................................................................. 150
Appendix D. Front panel cut-out drawing ......................................................................... 152
MJK cut-out download...................................................................................................... 153
Appendix E. MJK test certificate.......................................................................................... 154

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Appendix F. Log files ............................................................................................................ 155
Appendix G. Digital input/output connections ................................................................. 159
Appendix H. Remote slave display unit .............................................................................. 160
Connection board for remote slave display unit ........................................................... 161
Converter connection board with master display unit ................................................. 162
Wiring.................................................................................................................................. 163
Configuration for the master unit .................................................................................... 163
Configuration for the slave unit ....................................................................................... 163
Main menu overview ............................................................................................................. 164
Converter setup menu overview ......................................................................................... 166
Service menu overview ......................................................................................................... 172
Display setup menu overview .............................................................................................. 176

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Contact
You can always contact your local representative or the MJK hotline for advice
and guidance:
Europe: Tel.: [phone], e-mail: [email protected]
Visit our web site www.mjk.com to learn more about MJK Automation, our
other products and the people behind them.

MagFlux® Series
EN 3.05 Version 2102
MJK declaration of conformity /
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MJK declaration of conformity

MagFlux® Series
EN 3.05 Version 2102
Introduction /Introduction - MagFlux® Q
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1.
Introduction
The MagFlux® is suitable for flow measurement in all kinds of conductive 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.
Introduction - MagFlux® Q
MagFlux® Q is especially suited for seawater and similar conditions as it is
created in ABS plast, no outer parts in metal.
Operating principles
The MagFlux® 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 above, 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.
E = 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

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Introduction /The MagFlux® Flow Meter
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2.
V is the fluid velocity
k is a dimensionless constant
The flow of the fluid Q (m3/s) is given by the following formula:
Q = π x 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 1. and 2. gives 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.
The MagFlux® Flow Meter
Measurement
Electromagnetic flow meters may have either direct current (DC) or alternating
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 because the voltage induced over the electrodes will be a DC voltage.
The drawbacks are measurement errors due to electrochemical polarization
between the electrodes and the fluid.
The MagFlux® 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 activated 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.

MagFlux® Series
EN 3.05 Version 2102
Safety, repair and product identification /Safety instructions
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2.
3.
4.
Safety, repair and product identification
Safety instructions
Read this manual carefully.
Pay attention to the environment on the installation site.
Wear necessary protective equipment and follow all current safety
regulations.
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 configuration, fault
finding, servicing, maintenance work, etc.
Warning: There is a risk of lethal, electrical shock from Mains supply terminals
named N and L or - and +. Be careful not to touch these terminals - marked in
red in the following - while the MagFlux® is being serviced.
10-30 VDC
24 VAC

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EN 3.05 Version 2102
Safety, repair and product identification /Physical mounting
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115 VAC
230 VAC
Physical mounting
The MagFlux® flow converter/flow meter must not be mounted in explosion
hazardous areas!
Repair
Repair must only be made by this company or by a service representative
approved by us.
MJK 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, serial number, calibration code and electrode/lining data are
printed on an identification label on the flow sensor (see the following
example):

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Safety, repair and product identification /MJK product identification
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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 eight character input, but also
accepts six characters plus two OK. The current example (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 lower case letters can be
entered via 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 Initial setup(see page54)).

MagFlux® Series
EN 3.05 Version 2102
Flow sensor /Minimum conductivity
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Flow sensor
The following conditions must be obtained to get the full benefit of the
MagFlux® flow sensor.
Minimum conductivity
The conductivity of the measured media must be greater than 5 µS/cm.
Liner selection
Use hard rubber lining for drinking water and waste water.
Liner selection, cont.
Use PTFE lining for chemicals and food industries
Use ABS lining for seawater (applies to MagFlux® Q only).
Electrode selection
Steel AISI 316TI-1.4571 for general purpose, sewage, water and
district heating systems
Hastelloy for sea water.
Tantalum, 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
PTFE 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
condensation, or consult factory for special builds for these locations.

MagFlux® Series
EN 3.05 Version 2102
Flow sensor /Mounting location
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Avoid air at the measuring point.
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.
However, the MagFlux® can be buried in a well or closed dug-down space. It is
created with a significant layer of protective paint preventing rust. But gravel
and dirt can wear the paint, thereby decreasing the level of protection.
Therefor, it is strongly recommended to leave a gravel-free and dry space for
the MagFlux® installation as illustrated below.
Important: Observe that the correct flow direction is set in the MagFlux®
Converter Setup menu and in the Service Menu. Default flow direction is A
(flow direction towards left).
The flow directions A or B are clearly shown on the name plate.

MagFlux® Series
EN 3.05 Version 2102
Flow sensor /Pressure loss
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Pressure loss
Pressure loss can easily be determined, if the nominal pipe diameter is greater
than the MagFlux® flow sensor. See this pressure loss diagram:
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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EN 3.05 Version 2102
Flow sensor /Accuracy
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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.
MJK sizing
The flow sensor should be selected so the flow velocity through the sensor will
be between 0.2-10 m/s. We recommend 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 in the following section.
Min and max flow, metrics
DN Qmin Qmax
0.2 m/s 10 m/s
[l/h] [l/h]
15 127 6362
20 226 11304
25 353 17676
32 579 28944
40 905 45360
50 1414 70560

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EN 3.05 Version 2102
Flow sensor /MJK sizing
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Min and max flow, metrics
DN Qmin Qmax
0.2 m/s 10 m/s
[m3/h] [m3/h]
65 2,39 119
80 3,62 181
100 5,65 283
125 8,84 442
150 12,7 636
200 22.6 1131
250 35.3 1767
300 50.9 2545
350 69.3 3464
400 90.5 4524
450 115 5726
500 141 7069
600 204 10179
700 277 13854
800 362 18095
900 458 22902
1000 565 28274
1200 814 40715
The Qmaxis equal to 20 mA factory preset.

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EN 3.05 Version 2102
Flow sensor /MJK sizing
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Min and max flow, imperial
Qmin Qmax
0.6 ft./s 30 ft./s
[GPM] [GPM]
½” 0.559 28.0
¾" 0.995 49.76
1” 1.550 77.82
1¼" 2.549 127.4
1½” 3.984 199.7
2” 6.226 310.7
2½” 10.52 523.9
3” 15.93 796.9
4” 24.87 1246
5” 38.92 1946
6” 55.91 2800
8" 99.50 4,979
10" 155.4 7,780
12" 224.1 11,205
14" 305.1 15,258
16" 398.5 19,919
18” 506.3 25,210
20” 620.8 31,120
24” 999.1 44,910
28” 1220 74,920
32” 1594 79,620
36” 2017 100,800
40” 2497 124,500
48” 3584 179,300

MagFlux® Series
EN 3.05 Version 2102
Flow sensor /Sizing chart
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Sizing chart
Example: A MagFlux® with an internal diameter of 100 mm can measure flow
rates between approx. 5.6 m3/h and 290 m3/hand the fluid velocity is 1.5 m/s
at a flow rate of approx. 42 m3/h.