Magnetic Flowmeters
Magnetic Flowmeters
Magnetic Flowmeters
MAGNETIC FLOWMETERS
10DX3111/3311 Design Level E
Sizes 1⁄2 through 12 Inches
PN25013
The following are trademarks of ABB Inc.:
COPA-XM
MAG-X ®
WARNING notices as used in this manual apply to hazards or unsafe practices which could result in
personal injury or death.
CAUTION notices apply to hazards or unsafe practices which could result in property damage.
NOTES highlight procedures and contain information which assist the operator in understanding the
information contained in this manual.
All software, including design, appearance, algorithms and source codes, is copyrighted by ABB
Inc. and is owned by ABB Inc. or its suppliers.
WARNING
POSSIBLE PROCESS UPSETS
Maintenance must be performed only by qualified personnel and only after securing equipment
controlled by this product. Adjusting or removing this product while it is in the system may
upset the process being controlled. Some process upsets may cause injury or damage.
NOTICE
The information contained in this document is subject to change without notice.
ABB Inc., its affiliates, employees, and agents, and the authors of and contributors to this
publication specifically disclaim all liabilities and warranties, express and implied (including
warranties of merchantability and fitness for a particular purpose), for the accuracy, currency,
completeness, and/or reliability of the information contained herein and/or for the fitness for any
particular use and/or for the performance of any material and/or equipment selected in whole or
part with the user of/or in reliance upon information contained herein. Selection of materials
and/or equipment is at the sole risk of the user of this publication.
This document contains proprietary information of ABB Inc., and is issued in strict confidence.
Its use, or reproduction for use, for the reverse engineering, development or manufacture of
hardware or software described herein is prohibited. No part of this document may be
photocopied or reproduced without the prior written consent of ABB Inc.
Table of Contents
SAFETY SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
i
Series 10DX3000 Magnetic Flowmeter Instruction Manual
Table List
ii
Series 10DX3000 Magnetic Flowmeter Instruction Manual
Figure List
iii
Series 10DX3000 Magnetic Flowmeter Instruction Manual
SAFETY SUMMARY
GENERAL POSSIBLE PROCESS UPSETS
WARNINGS Maintenance must be performed only by qualified personnel and
only after securing equipment controlled by this product. Adjusting
or removing this product while it is in the system may upset the
process being controlled. Some process upsets may cause injury or
damage.
RETURN OF EQUIPMENT
All Flowmeters and/or Signal Converters being returned to the fac-
tory for repair must be free of any hazardous materials (acids,
alkalis, solvents, etc.). A Material Safety Data Sheet (MSDS) for all
process liquids must accompany returned equipment. Contact the
factory for authorization prior to returning equipment.
INSTRUCTION MANUALS
Do not install, maintain or operate this equipment without reading,
understanding and following the proper instructions and manuals,
otherwise injury or damage may result.
II
Series 10DX3000 Magnetic Flowmeter Instruction Manual
SPÉCIFIQUES N’utilisez pas un ohmmètre de C.C pour cette mesure car les
ATTENTIONS effets de polarisation produiront des données complètement
incorrectes. (pg. 4-3)
I
Series 10DX3000 Magnetic Flowmeter Instruction Manual
READ FIRST
WARNING
INSTRUCTION MANUALS
Do not install, maintain, or operate this equipment without reading,
understanding and following the proper manufacturer’s instructions and
manuals, otherwise injury or damage may result.
RETURN OF EQUIPMENT
All Flowmeters and/or Signal Converters being returned to the
manufacturer for repair must be free of any hazardous materials (acids,
alkalis, solvents, etc). A Material Safety Data Sheet (MSDS) for all
process liquids must accompany returned equipment. Contact the
manufacturer for authorization prior to returning equipment.
Telephone:
E-Mail:
III
Series 10DX3000 Magnetic Flowmeter Instruction Manual
The NEMA 4X rating applies to the meter body and electronics enclosure only. The following
accessories (if supplied) may not meet NEMA 4X unless specifically ordered as NEMA 4X:
• meter flanges
• meter installation hardware: studs, nuts, bolts
• enclosure mounting hardware for pipe or wall mounting
• conduit hardware
This product is painted with a high performance epoxy paint. The corrosion protection provided by
this finish is only effective if the finish is unbroken. It is the users’ responsibility to "touch-up" any
damage that has occurred to the finish during shipping or installation of the product. Special attention
must be given to: meter flange bolting, pipe mounting of electronics, conduit entries and covers that
are removed to facilitate installation or repair. For continued corrosion protection throughout the
product life, it is the users’ responsibility to maintain the product finish. Incidental scratches and other
finish damage must be repaired and promptly re-painted with approved touch-up paint. Provide the
model number and size of your product to the nearest factory representative to obtain the correct
touch-up paint.
IV
Series 10DX3000 Magnetic Flowmeter Instruction Manual
1.0 INTRODUCTION
1.1 General
1.1.1 Description
The Series 3000 Magnetic Flowmeter is a compact, volumetric, liquid flow rate detector that uses as
the process transducing method the characteristic of a conductive liquid to generate an induced
voltage when flowing through a magnetic field. The amplitude of the voltage produced is directly
proportional to the flow rate of the metered liquid.
Being a completely obstructionless metering instrument, the Series 3000 Magnetic Flowmeter can be
used to meter liquids without regard to heterogeneous consistency and is as independent of the
tendency to plug or foul as the pipeline in which it is mounted. An inherent advantage of obstruction-
less construction is that pressure losses are reduced to levels occurring in equivalent lengths of
equal diameter pipeline. This reduces or conserves pressure source requirements in new or existing
hydraulic lines as compared to other metering methods. The compact size of the meter results in a
light-weight unit which requires no additional support other than that used normally on pipe runs.
Short laying lengths minimize the need for altering existing pipe runs to accommodate metering. A
basic construction of corrosive resistant wetted parts and a variety of meter lining materials permit
metering of most corrosive and reactant liquids.
Factors such as liquid viscosity and density require no compensation and have no effect on the
measurement accuracy of the Magnetic Flowmeter. Metering limitations are confined to a minimum
threshold of electrical conductivity inherent to the liquid being metered. The degree of liquid conduc-
tivity has no effect upon metering accuracy as long as it is greater than this minimum level. Liquid
temperature is limited only to the extent that it may affect liquid conductivity and, like liquid pressure,
to the extent that it can not exceed the meter material specification limits.
The associated electronics package is called the Signal Converter and may be either integrally or
remotely mounted. Either an analog or a microprocessor signal converter may be used with the
Series 3000 Magnetic Flowmeter. The Flowmeter without the electronic package is used with a
remote mounted Signal Converter. A remotely mounted Signal Converter is recommended for any or
all of the following conditions:
• if the summation of ambient and process temperature is greater than 262 o F
(110o C) for COPA-XM, the Signal Converter must be remotely mounted.
• vibrations above the specification given in Section 1.3
The Signal Converter also contains a magnet driver unit that is used to power the meter’s magnet
coils. The steady bipolar state magnetic field principle, referred to as the MAG-X® design concept,
provides optimum zero point stability at an optimized drive frequency.
For information concerning the Signal Converter, refer to the Signal Converter Instruction Manual.
1.1.2 Construction
The Series 3000 Magnetic Flowmeter consists of a flanged, stainless steel pipe spool which serves
as a meter body. A pair of flat magnet coils fit on opposite sides of the meter housing inner surface.
Permeable iron straps and pole pieces focus the magnetic field generated by the coils and provide a
flux return path.
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Series 10DX3000 Magnetic Flowmeter Instruction Manual
The NEMA 4X rating applies to the meter body and electronics enclosure only. The following
accessories (if supplied) may not meet NEMA 4X unless specifically ordered as NEMA 4X:
• meter flanges
• meter installation hardware: studs, nuts, bolts
• enclosure mounting hardware for pipe or wall mounting
• conduit hardware
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Series 10DX3000 Magnetic Flowmeter Instruction Manual
1-3
Series 10DX3000 Magnetic Flowmeter Instruction Manual
Engineering Reference
Obstructionless Remote Magnetic Flowmeter
Design Level
Remote with 50XM1000 Converter Electronics E
Liner Material
Hard Rubber A
Polyurethane D
PTFE Teflon E
Neoprene L
TEFZEL N
Size
mm (inches)
15 (1/2) 07
25 (1) 09
40 (1-1/2) 11
50 (2) 12
80 (3) 14
100 (4) 15
150 (6) 17
200 (8) 18
250 (10) 19
300 (12) 20
Flange Material
Carbon Steel 1
304 Stn. Steel 2
Electrode Type
Flush 2
Bullet Nose 3
Flush (Slurry Service) 7
1-4
Series 10DX3000 Magnetic Flowmeter Instruction Manual
Electrode Material
316 Stn. Steel B
HASTELLOY® B C
HASTELLOY® C D
Titanium E
Tantalum F
Platinum / Iridium H
Zirconium L
Certification
Standard (None) A
Enclosure Classification
IEC 529 IP 65, NEMA 4X 1
Accidental Submergence: IEC 529, IP 67, NEMA-4X. 33ft H2O/48h (10m H2O/48h) 2
Accidental Submergence: IEC 529, IP 67, NEMA-4X. 33ft H2O/48h (10m H2O/48h) 4
Tropical-High Moisture Protection, Signal Cable Permanently Installed.
Continuous Submergence: IEC 529, IP 68, NEMA-4X. 33ft H2 O/48h (10m H2 O/48h) 5
Continuous Duty. Signal Cable Permanently Installed.
Accidental Submergence: IEC 529, IP 67, NEMA-4X. 33ft H2O/48h (10m H2O/48h)
Tropical-Improved Moisture Protection, Signal Cable Permanently Installed. 9
Converter Type
50XM1000 1
none X
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Series 10DX3000 Magnetic Flowmeter Instruction Manual
Design Level
Integral with 50XM1000 Converter E
Electronics
Liner Material
Hard Rubber A
Polyurethane D
PTFE TEFLON E
Neoprene L
TEFZEL N
Size
mm (inches)
15 (1/2) 07
25 (1) 09
40 (1-1/2) 11
50 (2) 12
80 (3) 14
100 (4) 15
150 (6) 17
200 (8) 18
250 (10) 19
300 (12) 20
Flange Material
Carbon Steel 1
304 Stn. Steel 2
Electrode Type
Flush 2
Bullet Nose 3
Flush (Slurry Service) 7
Electrode Material
316 Stn. Steel B
HASTELLOY B C
HASTELLOY C D
Titanium E
Tantalum F
Platinum/Iridium H
Zirconium L
Certification
General Purpose A
1-6
Series 10DX3000 Magnetic Flowmeter Instruction Manual
Enclosure Classification
IEC 529 IP 65, NEMA 4X 1
Line ExcitationFrequency
50 Hz / 6-1/4 Hz 1
50 Hz / 12-1/2 Hz 2
60 Hz / 7-1/2 Hz 3
60 Hz / 15 Hz 4
12-1/2 Hz (DC Power, in vicinity of 50 Hz Line) 6
15 Hz (DC Power, in vicinity of 60 Hz Line) 8
Other Frequency 9
Software Level
Generation X
Option Terminals
None A
Alarm, Opto-coupled D
External Zero Return F
External Totalizer Reset G
Forward Pulse Output, Opto-coupled K
Accessories
Without A
Empty Pipe Detection (standard) B
HART Protocol C
Empty Pipe Detection & HART Protocol D
Power Supply
230/240 V, 50/60 Hz A
200/220 V, 50/60 Hz B
115/120 V, 50/60 Hz C
100/110 V, 50/60 Hz D
48 V, 50/60 Hz E
24 V, 50/60 Hz F
48 VDC G
24 VDC H
Converter
Required 1
Not-Required 2
1-7
Series 10DX3000 Magnetic Flowmeter Instruction Manual
1.3 Specifications
Power Requirements Refer to Section 1.2 Model Number Breakdown.
Flowmeter
Characteristics
Rangeability 100:1
Meter Capacity Specified on Flowmeter data tag (equal to maximum flow capac-
ity in engineering units). Refer to Table 1-4.
Environmental Limits
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Series 10DX3000 Magnetic Flowmeter Instruction Manual
Process Limits
Temperature
o o
Flange Flange 100 F 175 F 190o F 266o F 356o F
Class Material [38o C] [80 o C] [88o C] [130o C] [180o C]
Carbon Steel 1.96 (285) 1.79 (260) 1.81 (262) 1.65 (240) 1.47 (213)
ANSI 150
304 sst 1.90 (275) 1.69 (245) 1.65 (239) 1.48 (215) 1.32 (191)
Carbon Steel 5.10 (740) 4.76 (690) 4.70 (682) 4.56 (662) 4.44 (644)
ANSI 300
304 sst 4.96 (720) 4.34 (630) 4.22 (612) 3.82 (554) 3.42 (496)
Carbon Steel 0.60 (87) 0.60 (87) 0.60 (87) 0.59 (86) 0.57 (82)
DIN PN6
304 sst 0.58 (84) 0.57 (82) 0.57 (82) 0.54 (79) 0.50 (73)
Carbon Steel 1.00 (145) 1.00 (145) 1.00 (145) 1.00 (145) 1.00 (145)
DIN PN10
304 sst 0.97 (140) 0.94 (137) 0.94 (137) 0.92 (133) 0.88 (128)
Carbon Steel 1.60 (232) 1.60 (232) 1.60 (232) 1.60 (232) 1.60 (232)
DIN PN16
304 sst 1.54 (224) 1.51 (219) 1.50 (218) 1.46 (212) 1.41 (205)
Carbon Steel 2.50 (362) 2.50 (362) 2.50 (362) 2.50 (362) 2.50 (362)
DIN PN25
304 sst 2.43 (352) 2.28 (331) 2.25 (327) 2.10 (304) 1.93 (280)
Carbon Steel 4.00 (580) 4.00 (580) 4.00 (580) 4.00 (580) 4.00 (580)
DIN PN40
304 sst 3.89 (564) 3.65 (530 3.62 (525) 3.36 (488) 3.10 (449)
Temperature
o o
Liner 68 F 212 F 266 o F 356o F
Meter Size Material [20 o C] [100 o C] [130o C] [180o C]
1/2 -4 in TEFLON/
Full Vacuum To 266 o F [130o C] 6.7 psia
(15-100 mm) TEFZEL
6-12 in TEFLON/
3.9 psia 5.8 psia 6.7 psia 8.7 psia
(150-300 mm) TEFZEL
Neoprene
Full Vacuum To 190 o F [88 o C]
Polyurethane
All
Soft & Hard
Full Vacuum To 175 o F [80 o C]
Rubber
1-9
Series 10DX3000 Magnetic Flowmeter Instruction Manual
Flow Ranges
Meter Meter 0 to Value Tabulated
Size Capacity* Minimum Maximum
inch mm gpm gpm L/min gpm L/min
1⁄2 15 26.4172 0.5 2.0 26.4 100.0
1 25 52.8344 1.06 4.0 52.8 200.0
1 ⁄2
1 40 158.503 3.17 6.0 158.0 600.0
m3 /h m3 /h
2 50 264.372 5.28 1.2 264.0 60.0
3 80 792.516 15.85 3.60 792.0 180.0
4 100 1056.68 21.14 4.80 1056.0 240.0
6 150 2641.72 52.84 12.0 2641.0 600.0
8 200 4755.09 95.11 21.6 4755.0 1080.0
10 250 7925.16 158.5 36.0 7925.0 1800.0
12 300 10566.8 211.4 48.0 10567.0 2400.0
* Each meter is calibrated to determine its flow capacity at a given velocity, which has been
established as 32.808 ft/s (10 m/s) for the Meter Capacity. The Meter Capacity expressed in gpm is
recorded on the meter nameplate.
All series 3000 meters are calibrated at 32.808 ft/s (10 m/s). Note that the display on the Signal
Converter supplied may read "Cal Factor" even when configured for 32.808 ft/s (10 m/s).
The Meter Capacity is the base upon which maximum and minimum limits for range
settings and outputs are established.
Meter Capacity:
NOTE
The maximum meter flow range is a function of the Signal
Converter used. The maximum flow range may exceed the meter
capacity to allow for overrange.
1-10
Series 10DX3000 Magnetic Flowmeter Instruction Manual
Physical Characteristics
NOTE
A remotely mounted Signal Converter must be used when vibration
limits are exceeded.
Permanently
Installed:
Non-Permanently
Installed:
Materials of
Construction
Electronics Housing cast aluminum, epoxy finish, 316 sst attachment screws,
gasketed covers
1-11
Series 10DX3000 Magnetic Flowmeter Instruction Manual
NOTE
Enclosures are suitable for indoor or outdoor installation. Enclosure
ratings apply to the Magnetic Flowmeter with or without an integral
Signal Converter.
1-12
Series 10DX3000 Magnetic Flowmeter Instruction Manual
2.0 INSTALLATION
2.1 Inspection
All Series 3000 Magnetic Flowmeters are shipped in heavy duty containers which are specially
designed to provide adequate protection during transit. Since the Magnetic Flowmeter will be
operated in conjunction with an electronic Signal Converter, both instruments may be in the same
shipping container. An itemized list of all items included in the shipment is attached to the shipping
container. Refer to the Instruction Bulletin supplied with the associated Signal Converter for opera-
tion and maintenance procedures for the particular Converter.
If the specified Magnetic Flowmeter is supplied with a remote Signal Converter, thirty feet of
interconnection cable(standard) and conduit or cable seals will be included in the shipment.
Inspect all items included in the shipment immediately for indications of damage which may have
occurred during shipment. All damage claims should be reported to the shipping agent involved
before attempting to install or operate this equipment. If the damage is such that faulty operation is
likely to result, the damage should be brought to the attention of the Service Department.
When a TEFLON lined meter is specified, two liner protector plates (one on each flange face) are
factory installed (when specified at time of order). These plates serve to contain the flared ends of the
liner, and to prevent damage to the liner during installation and handling. These protector plates are
attached to the meter with flat head screws that securely hold the liner in place. If the pressure on the
liner is relieved, the TEFLON will tend to curl away from the flange. These protector plates must
remain in place when the meter is installed. Refer to Figure 2-1 for a view of these protector plates.
Also, due to the susceptibility of the meter to moisture penetration behind the liner before installation
in the pipeline, TEFLON-lined meters should not be stored outdoors in uncovered areas, in wet
locations or subjected to cleaning operations with excessive liquids prior to being fully installed in the
pipeline.
During shipment, the liner is protected by wood or composition protectors as shown in Figure 2-2
(standard); these are removed before the meter is installed. These protectors should be left in
position while moving the meter to the installation site. In the case of wood protectors, make certain
there are no wood chips between the liner and the meter flange face prior to installation.
To place the meter in the pipeline a sling and hoist may be necessary. Do not pass any rope or wire
sling through the meter; the liner will be damaged if the meter is supported by the liner. Lift the meter
as shown in Figure 2-2.
Table 2-1 lists the weights of the meters by size and flange classification. Weights shown are
approximate and should be used only as a guide when installing the meter.
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Series 10DX3000 Magnetic Flowmeter Instruction Manual
If the continuous submergence option is chosen for Model 10DX3111/3311, the meter weights shown
above must be modified by adding the weights in the following table:
2-2
Series 10DX3000 Magnetic Flowmeter Instruction Manual
2-3
Series 10DX3000 Magnetic Flowmeter Instruction Manual
2-4
Series 10DX3000 Magnetic Flowmeter Instruction Manual
2.3 Location
The Flowmeter is suitable for either indoor or outdoor installation. When selecting the location of the
installation, consideration should be given to the ambient and process temperature limits, as stated
in the Specifications Sub-Section 1.3.
• The Standard meter is rated NEMA 4X (IEC 529 IP65), watertight, and will
withstand periods of rain and hose down.
• If periodic flooding may occur, an optional NEMA 4X (IEC 529 IP67)
accidental submergence Flowmeter is available to withstand submergence
up to 48 hours. These ratings apply to TEFLON-lined meters only after the
meter is properly installed in the pipeline.
• If periodic flooding is expected to keep the meter submerged for periods
longer than 48 hours, an optional continuous submergence NEMA 4X (IEC
529 IP68) configuration is available.
It is recommended that the meter not be installed in the immediate vicinity of electrical conductors
carrying large currents or equipment generating strong magnetic fields.
Access for wiring interconnections and servicing of the integrally mounted Signal Converter should
be considered when installing the meter. A minimum of five inches of overhead clearance is required
for cover removal.
Outline dimensions of the Flowmeter are given in Figures 2-3 through 2-16.
Outline dimensions of the optional remotely mounted Signal Converter are given in the Instruction
Manual supplied with the Signal Converter.
The installation site must be provided with a convenient source of power as specified for the Signal
Converter. The power line should have a disconnect switch and a suitable fuse or circuit breaker as
shown on the applicable interconnection diagram provided in the Instruction Bulletin supplied with the
Signal Converter.
2-5
Series 10DX3000 Magnetic Flowmeter Instruction Manual
Ref. OD-10D-4293 r0
2-6
Series 10DX3000 Magnetic Flowmeter Instruction Manual
2-7
Series 10DX3000 Magnetic Flowmeter Instruction Manual
2-8
Series 10DX3000 Magnetic Flowmeter Instruction Manual
2-9
Series 10DX3000 Magnetic Flowmeter Instruction Manual
Ref. OD-10D-4287 r1
2-10
Series 10DX3000 Magnetic Flowmeter Instruction Manual
Ref. OD-10D-4123 r4
2-11
Series 10DX3000 Magnetic Flowmeter Instruction Manual
Ref. OD-10D-4127 r3
2-12
Series 10DX3000 Magnetic Flowmeter Instruction Manual
Ref. OD-10D-4288_r1
2-13
Series 10DX3000 Magnetic Flowmeter Instruction Manual
Ref. OD-10D-4194 r2
& OD-10D-4231 r0
2-14
Series 10DX3000 Magnetic Flowmeter Instruction Manual
Ref. OD-10D-4195
& OD-10D-4232
2-15
Series 10DX3000 Magnetic Flowmeter Instruction Manual
2-16
Series 10DX3000 Magnetic Flowmeter Instruction Manual
2-17
Series 10DX3000 Magnetic Flowmeter Instruction Manual
2-18
Series 10DX3000 Magnetic Flowmeter Instruction Manual
2-19
Series 10DX3000 Magnetic Flowmeter Instruction Manual
2.4 MOUNTING
2.4.1 Orientation
The Series 3000 Magnetic Flowmeter may be installed in horizontal, vertical or sloping pipe runs.
However, precautions must be taken to assure that the metering tube is filled at all times during
measurement. A vertical installation, with the pipe line carrying liquid upwards assures a filled
hydraulic line under low flow rate conditions and also minimizes wear on the meter lining by abrasive
grit. Horizontal installations should be made with the meter in the lower section of a pipeline to assure
a filled meter condition.
For horizontal or sloping installations the meter should be placed so that the electronic housing of the
meter is on top. This will align the meter electrodes in a lateral plane. Positioning the meter in this
way eliminates the possibility of entrained air acting as an electrode insulator.
The Magnetic Flowmeter must be oriented in accordance with the direction of process flow, as
indicated by the FLOW arrow on the meter body. For accurate metering, a straight pipe run
equivalent to a minimum of three straight pipe diameters are required upstream of the magmeter for
elbows and tees, measured from the center of the meter (refer to Figure 2-17).
If a control valve is required, it is recommended that it be placed downstream of the meter. Upstream
valves can create turbulence that result in air pockets and may affect the meter’s accuracy or cause
its output to be noisy. A minimum of ten pipe diameters of straight pipe are required upstream
between the magmeter and a control valve or pump (refer to Figure 2-17).
NOTE
Leave metal protector plates or plywood lining protectors in place on
the meter until the meter is ready to be installed, otherwise the Teflon
meter liner will have a tendency to "flare" away from the meter face and
may make meter installation difficult.
2-20
Series 10DX3000 Magnetic Flowmeter Instruction Manual
2-21
Series 10DX3000 Magnetic Flowmeter Instruction Manual
For liner materials other than those shown in the tables, the flange bolts should be tightened
sufficiently to stop any leaks but should not exceed the values shown in the tables.
NOTE:
• Torques listed are for bolts with threads lubricated
• All meters with PTFE liners need to be re-torqued after 48 hours of operation
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Series 10DX3000 Magnetic Flowmeter Instruction Manual
2.4.5 Gaskets
Use only the gaskets supplied with the instrument. The gaskets supplied with the meter are the
proper size for the meter size and type specified. When installing the meter it is important that the
correct size gaskets be utilized. Use of the wrong size gaskets could allow the inner diameter of the
gasket to protrude into the flow stream, thereby altering the flow profile within the meter. This
condition could affect meter accuracy significantly and must be avoided. Using the proper gaskets
and installing them correctly will also avoid any possibility of leakage. Observe parts information
given in Section 6.0. Refer to Figure 2-19 for proper gasket locations.
NOTE
Do not use graphite gaskets. Under certain conditions they
may cause an electrically conductive layer to form on the in-
side wall of the meter, causing meter operation to degrade.
2-23
Series 10DX3000 Magnetic Flowmeter Instruction Manual
Meter grounding requirements are really a combination of standard grounding methods and a
bonding of the meter body to the process liquid. The most important of these is the process bonding,
which is nothing more than ensuring that the meter body is in contact with the process liquid at both
ends of the meter body. Basically, the bonding procedure places an electrical short circuit across the
meter, thereby routing any stray current around the liquid in the meter (rather than through it).
From the point of view of grounding there are two basic types of piping systems:
• electrically conductive pipeline: the process liquid comes in contact with
conductive pipe. This piping requires that each meter flange be connected
with a bonding wire to the adjacent pipeline flange. The grounding procedure
to use with conductive pipeline is described in 2.5.2.
• non-conductive or electrically insulated pipeline: the pipeline may be made of
an electrically non-conductive material (plastic, concrete, etc.) or lined with a
non-conductive material (rubber, TEFLON, etc). These non-conductive
pipelines require the use of metal grounding rings to bond the process liquid
to ground. The grounding procedure to use with nonconductive pipeline is
described in 2.5.3.
Proper grounding of the Magnetic Flowmeter is required for optimum system performance.
1) Drill and tap both pipeline flanges adjacent to the bonding connections on the
flowmeter. The lugs on the bonding cables are sized for metric M6 fasteners (a 1/4"
bolt).
2) Obtain a bright metal surface around the edges of the tapped hole with a file or
burnishing tool.
3) Attach the bonding wire and another length of ground wire to the flanges as shown.
Use internal tooth lockwashers as shown in the detail. The wire to the good external
ground should be #12 AWG, or heavier, copper wire.
2-24
Series 10DX3000 Magnetic Flowmeter Instruction Manual
1) For this service, the meter requires the use of grounding rings. The grounding rings
should be installed between the meter flanges and the mating flanges of the pipeline
as shown in Figure 2-21. A gasket is required on both sides of the grounding ring. If
the meter is supplied with a grounding ring/protector plate fastened to the meter
flange,only one gasket is required between the grounding ring/protector plate and the
pipeline flange. Proper gasket locations are shown in Figure 2-19.
NOTE
When using grounding rings and gaskets, add 1/8 inch per end (1/4 inch
total) to the overall meter installation length (dimension "L" in Figures
2-3 through 2-16) to allow for the added thickness of these items.
2) Attach the bonding wire and ground wire to the tab of the grounding ring. Use
internal tooth lockwashers and hex head nut and bolts as shown in Figure 2-21. The
ground wire should be #12 AWG, or heavier, copper wire.
2-25
Series 10DX3000 Magnetic Flowmeter Instruction Manual
WARNING
ELECTRICAL SHOCK HAZARD. Equipment powered by ac line voltage
constitutes a potential electric shock hazard to the user. Make certain
that the system power input leads are disconnected from the operating
branch circuit before attempting electrical interconnections.
Regardless of the interconnection procedure used, the grounding procedures given in Section 2.5
must be followed.
For explosion proof meter installation, all interconnection wiring must be installed according to
National Electrical Code (NEC) ANSI/NFPA 70 Section 500.
NOTE
For meters capable of continuous submergence, the signal cable has
been permanently installed by the factory. Do not loosen the cable seal
fitting or remove the connection box lid since this will break the seal
and void the warranty.
2-26
Series 10DX3000 Magnetic Flowmeter Instruction Manual
Integral Converter - Feed-through’s between the electronics housing and field wiring
(customer connection) junction box.
Remote Primary - Conduit entry cable seal on meter customer connection box.
It is the user’s responsibility to properly install the conduit entry cable seal fitting supplied with the
signal cable provided with the remote mounted signal converter. This will ensure proper performance
of this safety feature. See Figure 2-22.
A pressure relief is provided in the electronics housing for the integrally mounted signal converter
and in the customer connection box on the remote mounted Flowmeter. In both housings, the
pressure relief is located in the center of the cover joint on the side opposite from the conduit
connection. If the primary seal should fail, the pressure relief will vent the process preventing an over
pressurization and potentially dangerous failure of the electronics housing.
It is the user’s responsibility to be aware of this safety feature and to consider the unlikely event of its
functioning. Based on knowledge of the process and meter application, the user should consider the
installation orientation of the meter and possible use of deflectors to safely direct the vented process.
2-27
Series 10DX3000 Magnetic Flowmeter Instruction Manual
There are no operating controls that require field adjustment unless the full scale range setting was
not specified. If a change in the full scale range setting is required, refer to the Instruction Bulletin
supplied with the Signal Converter. If no change is required, the equipment is ready for operation as
received.
Prior to initial system start up, verify that the meter is properly installed; check flow direction, wiring
interconnection and grounding as discussed in Section 2.0 Installation. Particular attention should be
given to the meter grounding procedures; improper grounding may result in unsatisfactory perform-
ance. Refer to the Signal Converter Instruction Bulletin for interconnection grounding.
Start flow through the process piping system that includes the meter. Allow a nominal flow through
the pipeline for several minutes to purge entrapped air. The pipeline must be full for accurate flow
measurement.
Apply the appropriate power for the 10DX3111 Magnetic Flowmeter by closing the external switch or
circuit breaker; there are no switches inside of the equipment. Also energize any auxiliary equipment
associated with the flow metering system, such as remote analog recorders, controllers or rate
indicators.
Initiate process flow through the pipeline. Flow measurement and concurrent output signal transmis-
sion will commence with flow through the meter. Information concerning operation of the Signal
Converter is provided in the Instruction Manual supplied with the Converter.
3-1
Series 10DX3000 Magnetic Flowmeter Instruction Manual
POWER
CONNECTOR
BASE BOARD
GROUND
TERMINAL
INTERCONNECTION &
CUSTOMER CONNECTIONS
3-2
Series 10DX3000 Magnetic Flowmeter Instruction Manual
CUSTOMER
CONNECTIONS
GROUND
TERMINAL
3-3
Series 10DX3000 Magnetic Flowmeter Instruction Manual
CABLE
CONNECTIONS
NOTE
Figure 3-5 shows Explosion-Proof configuration. The Continuous
Submergence model is identical to that shown except that the housing
is filled with a silicone rubber encapsulant.
3-4
Series 10DX3000 Magnetic Flowmeter Instruction Manual
The Flowmeter provides two output signals to the associated signal converter:
• an electrode signal that contains the flow rate information
• the reference signal which is proportional to the magnet excitation current
(theoretically, this reference signal is proportional to the flux density in the metering
section).
The reference voltage is derived across a precision "constant meter factor" resistance network that is
connected in series with the magnet coils. Changes in magnet drive voltage, which cause a variation
of flow signal, will simultaneously cause a proportional variation of the reference voltage. The
circuitry will provide an exact ratio and thereby provide immunity to power supply variation. The
magnet coil drive circuitry is contained in the signal converter.
4-1
Series 10DX3000 Magnetic Flowmeter Instruction Manual
(Equation #1)
1
Es = BDV
α
where:
Thus, the metered liquid constitutes a continuous series of conductive liquid disks moving through a
magnetic field. The more rapid the rate of liquid flow, the greater the instantaneous value of signal
voltage as monitored at the meter electrodes.
(Equation #2)
V = Q = 4Q
A πD 2
4
E s = 1 BD Q2
α πD
4-2
Series 10DX3000 Magnetic Flowmeter Instruction Manual
Since B = β E r
(Equation #3)
Q = γ Es
Er
where:
Therefore, volumetric flow rate is directly proportional to the induced signal voltage as measured by
the magnetic flowmeter.
The conductivity of a given liquid, σ, may be determined experimentally under a filled meter
condition, as follows:
1) Remove the Converter housing cover. Disconnect the electrode signal interconnection leads
from terminals "1" and "2" of the signal converter. (These leads should be identified so that they will
be properly reconnected.)
2) Measure the resistance between signal leads "1" and "2" with an ac ohmmeter.
CAUTION
Do not use a DC ohmmeter for this measurement as polarization
effects will produce completely erroneous data.
4-3
Series 10DX3000 Magnetic Flowmeter Instruction Manual
The conductivity of the process liquid (in microsiemens/cm) may be determined from the electrode ac
resistance measurement (in megohms) by substitution of values in the following equation.
σ= 1
(R ac - 0.072) x Electrode Dia, in cm
where,
For example, assuming the measured ac electrode resistance (full pipe and zero flow) is 192,000
ohms and electrode diameter is 7.92 mm (0.792 cm), then
σ= 1 = 10.52 µS/cm
(0.192 - 0.072) x 0.792
This is above the threshold for specified measurement accuracy for the particular liquid, meter size
and signal converter combination. Liquid conductivities at the operating temperature may also be
determined from standard reference works for many pure liquids. Company Field Engineers are
equipped to determine the conductivities of special liquids at the user’s site as an engineering
service.
4.2.1.2 Liquid Temperature
Having established the minimum liquid conductivity requirements for a given application, any liquid
which exhibits equal or higher conductivity may be metered without concern for any system compen-
sating adjustments. However, due regard for the effect of the liquid conductivity versus temperature
should be considered.
Most liquids exhibit a positive temperature coefficient of conductivity. It is possible for certain
marginal liquids to become sufficiently non-conductive at lower temperatures so as to hamper
accurate metering. However, the same liquid at higher or normal environmental temperatures may be
metered with optimum results. The possibility of an adverse temperature conductivity characteristic
should be investigated before attempting to meter such a liquid. Process or ambient temperatures
are also limited by the meter materials specification.
Other normal effects of temperature, such as influence upon liquid viscosity and density, the size of
the metering area, and the flux density of the magnetic field, have negligible or no effect upon
metering accuracy.
4.2.1.3 Other Liquid Variables
Other liquid variables such as viscosity, density and liquid pressure have no direct influence on
metering accuracy. Liquid density has no effect on volumetric flow rate since only the area of the
meter pipe and liquid velocity are required to determine the rate of flow. Viscosity and metering
pressure are restricted to physical limitations alone, such as the leakage pressure of the meter pipe
flange connections.
4-4
Series 10DX3000 Magnetic Flowmeter Instruction Manual
The magnetic flowmeter will measure the total amount of material passing in the liquid stream. The
meter will not, for instance, differentiate between the amount of liquid and the amount of entrained
gases. Also, in the case of a slurry, it will not differentiate the amount of liquid from solids. If the liquid
to mixant ratio is of importance to process control, then separate measurements of the concentration
of the desired medium must be made and appropriate correction factors must be applied to the
magnetic flowmeter output.
The Flowmeter provides two output signals to the associated signal converter, an electrode signal
that contains the flow rate information and the reference signal which is proportional to the magnet
excitation current (theoretically, the reference signal is proportional to the flux density in the metering
section). The reference voltage is derived across a precision "constant meter factor" resistance
network that is connected in series with the magnet coils. Changes in magnet drive voltage, which
cause a variation of flow signal, will simultaneously cause a proportional variation of the reference
voltage. The circuitry will provide an exact ratio and thereby provide immunity to power supply
variation. The magnet coil drive circuitry is contained in the signal converter.
The (gated) magnet driver operates at a frequency that permits magnetic flux in the Flowmeter to
reach a steady state level during the last 25% of each half period of magnet excitation. By using
sampling techniques, the flow (differential mode) signal is measured only during the intervals that
magnetic flux is constant:
dΦ
dt = 0
Therefore, zero instability due to changing flux is eliminated by use of the MAG-X design concept
(sampling technique), providing a meter totally free of zero drift. A thorough discussion of signal
converter operation is provided in the Instruction Manual supplied with the particular signal converter.
4-5
Series 10DX3000 Magnetic Flowmeter Instruction Manual
Models 10DX3111/3311E flanged flowmeter primaries contain two flux producing coils wired in series
and a pair of diametrically opposed electrodes mounted at 90 degrees to the coil flux plane (refer to
FIGURE 4-2 below). Meter coils are excited with approximately +10 volts of pulsed DC. A precision
current sensing network is connected in series with the coils. The current sense network produces
what Fischer & Porter refers to as a "Reference Voltage", which is typically +70 millivolts. The
reference voltage is directly proportional to the strength of the magnetic field in the measuring tube
and is measured by the signal converter. The reference voltage must be measured, since any
variation in reference voltage will also produce a proportional change in electrode signal voltage,
assuming an unchanged flow velocity. The current sense (reference network) may be in the Primary
or the Secondary, depending on the model number and/or the design level.
1. Establishing interconnections between the Flowmeter internal wiring and the sig-
nal converter.
2. Permitting factory adjustment of meter capacity values to a fixed value for each
nominal size Flowmeter.
Meter coil current and, consequently, calibration factor are established by adjusting a precision
current-sense network which is in series with the meter coils. The current-sense network consists of
a low-resistance current-sensing resistor along with an adjustable resistive divider network placed
across the current-sense resistor. A potentiometer is also used to provide fine-tuning of the meter
capacity. Should this resistive network be damaged, repair and recalibration are only possible by
using precision electronic calibration instruments.
4-6
Series 10DX3000 Magnetic Flowmeter Instruction Manual
The full view of the 686B762U02 Primary Board Assembly is shown in Figure 4-3. Table 4-1 shows
selectable functions and their respective jumper settings.
4-7
Series 10DX3000 Magnetic Flowmeter Instruction Manual
4-8
Series 10DX3000 Magnetic Flowmeter Instruction Manual
1S 1 2 2S 3 3A 16 M3 M1
686B789U01 686B790U01
4-9
Series 10DX3000 Magnetic Flowmeter Instruction Manual
TERMINAL
39 40 - + V2 V1 V3 V4 L N
BLOCK
V3/V4 INACTIVE
Refer to the signal converter instruction manual for remote model 10DX3111E customer connection
terminals and functions.
4-10
Series 10DX3000 Magnetic Flowmeter Instruction Manual
5.0 MAINTENANCE
5.1 General
Except for an occasional performance verification check, there is no required routine maintenance for
the Series 3000 Magnetic Flowmeter. For practical reasons it is suggested that the meter body not be
disassembled. If disassembled, complete waterproof sealing is required for satisfactory operation
and is best done at the factory. Replacement of faulty magnet drive coils and electrode replacement
is a factory operation. Factory calibration after this type of repair is the only way to guarantee meter
accuracy.
WARNING
All Flowmeters and/or Signal Converters being returned to the factory for
repair must be free of any hazardous materials (acids, alkalis, solvents,
etc.). A Material Safety Data Sheet (MSDS) for all process liquids must
accompany returned equipment. Contact the factory for authorization
prior to returning equipment.
NOTE
Operation and maintenance procedures for the Signal Converter are pro-
vided in the instruction manual supplied with the Signal Converter.
When communicating with the company in regard to replacement of a complete meter (with integrally
mounted Converter), the meter body, or the Signal Converter, it is important to refer to the complete
instrument serial number to assure that the correct replacement will be supplied. This information is
provided on the manufacturing specification sheet supplied with the Magnetic Flowmeter, and on the
instrument data tag.
CAUTION
Some of the IC devices used in the signal
converter are static sensitive and may be damaged by improper handling.
When adjusting or servicing the signal converter, use of a grounded wrist
strap is recommended to prevent inadvertant damage to the integral solid
state circuitry.
5-1
Series 10DX3000 Magnetic Flowmeter Instruction Manual
NOTE
The Series 3000 Magnetic Flowmeter housing is supplied as a sealed unit.
Therefore, customer field repairs to these meters are not recommended. In
the event of a malfunction, repairs should only be performed by an author-
ized field service engineer, or the complete meter returned (shipping
charges prepaid) to the factory for service.
WARNING
ELECTRICAL SHOCK HAZARD. Equipment powered by an AC line voltage
presents a potential electric shock hazard. Servicing of the Magnetic
Flowmeter or Signal Converter should only be attempted by a qualified
electronics technician.
a) Remove access covers from the junction box and the Converter housing (remote or
integral).
b) Inspect for evidence of water entry in the junction box and Converter housing.
If water is present in either the junction box or converter housing of the flowmeter, immediately
de-energize system power to eliminate the possibility of a shock hazard.
The presence of water in either the converter housing or the terminal box atop the remote primary
most often results in irreparable damage to the circuit board assemblies inside. If such damage is
evident, the meter should be removed from the process pipeline and returned to the factory for repair.
It is also important that the source of the water-entry be found so that the situation doesn’t reoccur
when the meter is placed back into service.
Should water be found inside the wiring compartment of an integrally mounted converter housing, the
circuit board assembly in this section may be replaced in the field (Consult the factory for additional
instructions if this procedure becomes necessary).
5-2
Series 10DX3000 Magnetic Flowmeter Instruction Manual
2. Since signal wiring and operating procedures are dependent upon the type of Converter and the
mounting option selected, the user should refer to the instruction manual supplied with the associ-
ated Signal Converter for system troubleshooting procedures. A static performance test for the
primary mounted components is discussed in Section 5.3.
The Signal Converter options available for use with the Series 3000 Magnetic Flowmeter are eitheran
integrally or remotely mounted 50XM1000N Microprocessor-based Signal Converter
WARNING
ELECTRICAL SHOCK HAZARD. Equipment powered by an ac line voltage
presents a potential electric shock hazard. Make certain that the system
power is disconnected before making the following ohmmeter checks.
Measure the resistance between terminal 16 of the Primary connection board and the flowmeter
body. This resistance should measure between 10Ω and 500Ω.
5-3
Series 10DX3000 Magnetic Flowmeter Instruction Manual
Verify that the system power service has been de-energized. Loosen and remove the four screws
that hold the Signal Converter to the base. Disconnect the connector from signal (P1) on the CMC PC
board and the power (P3) connector to the Converter (refer to Figure 3-2) and set the Converter
module aside. Measure the series resistance of the magnet coils by connecting the ohmmeter
between terminals M1 & MR. The value displayed should be between 10Ω and 80Ω.
If it is suspected that process fluid or excess moisture has entered the Primary housing, unsolder the
coil wires from the M1 and MR pads. Verify that the resistance of each coil lead (M1, MR and CT) to
the flowmeter body is greater than 20 MΩ or infinite. If the resistance value is incorrect, the coils are
defective and the meter must be returned to the factory for service.
To thoroughly test the electrodes of flowmeters with remote converters (Model 10DX3111E), meters
must be tested under both full and empty pipe conditions. If this is not possible, it may still be helpful
to perform one of the tests since useful partial information may be gained from the results of either
portion of the test.
Electrode full pipe measurements should be made with the ohmmeter placed on its highest range. An
AC type ohmmeter (i. e. conductivity bridge) is preferred because DC voltage will tend to polarize the
electrode (but will nevertheless provide meaningful information). Connect the ohmmeter positive
lead first to electrode terminal "1" and then to electrode terminal "2" with the negative lead to terminal
"3" or the flowmeter body. The measured resistance should be 100,000 ohms plus the intrinsic
resistance between electrode and fluid (typically 50,000 additional ohms or less). If using a DC
ohmmeter, the resistance between the electrode and the fluid will tend to increase as the electrode
becomes polarized by a DC signal. This effect is normal. AC resistance readings will not vary once
established. Readings greater than 150,000 ohms may indicate a coated electrode. Infinite readings
indicate a broken connection in the electrode wiring path. Meters with infinite full pipe readings
should be returned to the factory for repair.
5-4
Series 10DX3000 Magnetic Flowmeter Instruction Manual
NOTE
Model 10DX3311E flowmeters with integrally mounted signal Converters in-
corporate a buffer preamplifier for each electrode. Since this preamplifier is
also encapsulated, an on-site evaluation of the condition of the electrodes
is not possible.
If the results of the procedures in Sections 5.3.2.1 through 5.3.2.3 indicate normal meter parameters,
the flowmeter may be returned to service.
Refer to the instruction manual supplied with the Signal Converter for additional advice on trou-
bleshooting flowmeter electronics.
5-5
Series 10DX3000 Magnetic Flowmeter Instruction Manual
NOTE
Polyurethane, neoprene & hard-rubber lined meters use neoprene
gaskets. TEFLON & TEFZEL lined meters use TEFLON gaskets.
Two gaskets are required for each meter. If the meter has grounding rings, two additional gaskets are
required for each meter.
6-1
Series 10DX3000 Magnetic Flowmeter Instruction Manual
TABLE 6-2. PROTECTOR PLATES FOR TEFLON & TEFZEL LINED METERS
Order number consists of two protector plates and mounting screws. Grounding rings are not
available for this application. When ordering, specify 614B452U__ and suffix from the table below.
Flange Rating
Protector Meter Size ANSI Class 300
Plate Material Inch = 4
(mm) = (100)
316 sst Suffix = 40
HAST "C" Suffix = 47
TABLE 6-3. LINER PROTECTOR/GROUNDING RINGS FOR TEFLON & TEFZEL LINED METERS
Order number consists of two protector plates and mounting screws. Grounding rings are not
available for this application. When ordering, specify 614B384U__ and suffix from the table below.
6-2
Series 10DX3000 Magnetic Flowmeter Instruction Manual
NOTE
Polyurethane, neoprene & hard-rubber lined meters use neoprene
gaskets. TEFLON & TEFZEL lined meters use TEFLON gaskets.
Order number consists of one grounding ring and mounting screws. Order a quantity of two for each
meter. Order by the referenced part number.
6-3
Series 10DX3000 Magnetic Flowmeter Instruction Manual
6-4
PN25013
ABB Inc. ABB Instrumentation Ltd ABB Instrumentation S.p.A ABB Automation Products GmbH
125 East County Line Road Howard Road, St. Neots Via Sempione 243 Industriestr. 28
Warminster, PA 18974 USA Cambs. England, PE19 3EU 20016 Pero (Milano) Italy D-65760 Eschborn Germany
Tel. 215-674-6000 Tel. +44 (0) 1480-475-321 Tel: +39 (02) 33928 1 Tel: +49 (0) 6196 800 0
FAX: 215-674-7183 FAX: +44 (0) 1480-217-948 Fax: +39 (02) 33928 240 Fax: +49 (0) 6196 800 1849