Installation and Use Manual for Plug in Electromagnetic Flow Sensor

Firstly, thank you to the esteemed user for choosing our companyPlug in electromagnetic flowmeter or other products. We believe that while using these high-quality products, you will also receive excellent technical services from our company.

l 1Purpose and Characteristics

l 1.1 The plug-in electromagnetic flow sensor (hereinafter referred to as the "sensor") is combined with our company's electromagnetic flow conversion display to form a plug-in electromagnetic flowmeter.

l Plug in electromagnetic flow meters are generally in separate types, but can also be combined into a single type if needed by users. The sensor is installed on the pipeline at the location where it needs to be detected,

l The split type conversion display can be installed on nearby walls or in instrument boxes with brackets, or in the instrument and control room. The two are connected by dedicated cables in the sensor junction box.

l The split type conversion display is directly installed on the top of the sensor.

l Plug in electromagnetic flow meters are used in industries such as industry, agriculture, water conservancy, and environmental wastewater monitoring in the national economy

l Various departments such as urban water supply are used to measure the flow rate and total amount of various conductive liquids.

l 1.2 characteristic

l The plug-in electromagnetic flowmeter has the characteristics of both pipeline electromagnetic flowmeter and plug-in flowmeter

l Point, these characteristics include:

l * The measurement is not affected by changes in fluid density, viscosity, temperature, pressure, and conductivity.

l * Adopting advanced excitation technology, with low power consumption, stable zero point, strong anti-interference ability, and good reliability.

l * No additional pressure loss, requiring a small length of straight pipe section.

l * The flow measurement range is wide, and the full-scale flow rate can be continuously set arbitrarily within 1.0m/s to 10.0m/s. The output signal is completely linearly related to the flow rate (flow velocity).

l * The conversion display adopts a 16 bit high-performance microprocessor, 2 × 16 LCD display, and convenient parameter setting,

l Programming is reliable.

l * The flowmeter is a bidirectional measurement system, equipped with three integrators that can display positive flow rate

l The total amount of reverse traffic and the difference between forward and reverse traffic.

l * The conversion display has multiple outputs: current, pulse, digital communication HART。

l * Suitable for large diameter pipelines, DN300—3000mm。

l * There are various materials to choose from for the sensor body and electrodes.

l * Small size, light weight, easy transportation and installation, capable of continuous flow maintenance and disassembly.

l * The price is cheap, and the larger the installation diameter, the higher the performance price ratio.

l 2Structure and Working Principle

l 2.1 structure

Figures (1) and (2) are two schematic diagrams of the overall structure of the sensor.

The upper end is a junction box, which is connected to a dedicated cable and an electromagnetic flow conversion display to form a split type electromagnetic flowmeter; If an electromagnetic flow conversion display is used instead of a junction box, it forms an integrated electromagnetic flowmeter

From the figure, it can be seen that the sensor consists of the following main parts or components:

·Detection head: including electrodes, excitation coils, iron cores, and leads, with a casing made of PVC or F4.

·Insertion rod: connects the detection head and the converter, made of 304 or 316 stainless steel.

·Installation component: (Φ 60 × 3) 304 or 316 stainless steel pipe, welded to the user's pipeline during installation.

·Valve or (short section): 2 "stainless steel ball valve or (short section), used to remove or install sensors under continuous flow conditions.

·Sealing and locking mechanism: including transition parts, compression nuts, and specialized sealing rubber rings.

·Junction box: The excitation current and signal of the sensor and converter are connected to each other in correspondence here.

2.1 Working principle

Its working principle is based on Faraday's law of electromagnetic induction, just like the pipeline type electromagnetic flow sensor. When a conductive liquid passes through two electrodes at a distance L with an average flow velocity V and perpendicular to the direction of magnetic field lines B, a corresponding electromotive force E is generated between the electrodes. Faraday's law of electromagnetic induction is:

E=B×L×V --（1）

The volume flow rate of fluid flowing through the pipeline is:

Q_V=----(2)

Since the sensor size has been determined, when

When knowing the diameter of the installed pipeline, it is calibrated and transmitted

The volumetric flow rate Q of the sensor is only positive for the electromotive force E

Compared to:

Q_V=K×E -------(3)

In the formula: K: instrument coefficient

The coefficient K is obtained from factory verification and has been provided by the user

Place the parameters into the conversion display (Users cannot make arbitrary changes) Figure (III) Schematic diagram of working principle

Among the various types listed above:

BMagnetic induction intensity of excitation coil

L: Distance between two electrodes (24mm for this machine)

V:average velocity

Q_V:Volume flow rate of the measured fluid

So as long as the electromotive force E is measured, the volumetric flow rate Q in the pipeline can be determined_V.

3、Main technical parameters and performance

3.1 Applicable flow pipeline nominal diameter: DN300-3000mm.

3.2 Working pressure: ≤ 1.6MPa. 1.0MPa

3.3 Working temperature: ≤ 70 ℃

3.4 Upper limit range of flow rate: continuously adjustable within 1-10m/s

3.5 Measurement accuracy: ± 2.5%

3.6 The conductivity of the measured medium is ≥ 50 μ s/cm.

3.7 Electrode materials: 304, 304L, 316, 316L, Hastelloy, titanium (Ti), etc

3.8 The maximum distance from the conversion monitor is ≤ 50m.

3.9 Cable: RVVP type dual core shielded cable or STT3200 type four core three shielded cable.

3.10Please refer to the user manual of our electromagnetic flowmeter for the function of converting the display.

4、Installation - Insertion and Removal

Reminder and Attention: Due to the pressure inside the pipeline, there is an outward thrust on the detection rod

*For safety reasons, it is best to use shutdown and install under non pressure conditions in the pipeline.

*If shutdown is not allowed, it is best to temporarily reduce the pipeline pressure to ≤ 0.2MPa during installation.

4.1Preparation before installation:

After receiving the instrument, users should do the following two things in advance:

4.1.1Before proceeding with installation work, please verify and confirm that the supply is correct. If any discrepancies are found between the supply and the contract, please contact our company promptly for resolution.

Please follow the following program steps for installation.

4.1.2According to Figures 1 and 2, lift the detection rod outward until the electrode is level with the lower end of the installation part, then measure and record the dimension L2.

4.2 Installation - Insertion

4.2.1The user pipeline should be set horizontally, with at least 5DN in front of the sensor and at least 3DN of straight pipe section behind it. The flow regulating valve should be located 3DN downstream of the sensor.

The user's pipeline should have no obvious vibration, and the inner wall of the pipeline should have no obvious unevenness.

4.2.2First, open a hole with a diameter of 60-62mm directly above the pipeline measurement point. The edges around the circular hole should be smooth, without burrs or gas cutting scars.

4.2.3Unscrew the installation component from the sensor and securely weld it to the above-mentioned opening, with the following requirements:

AAs shown in Figure (1), make the lower end of the installation part flush with the inner surface of the pipeline;

BEnsure no leakage.

4.2.4Loosen the three locking screws of the sensor and pull out the detection rod and detection head as a whole for later installation. (Note: Users are not allowed to open the connection between the detection head and the insertion rod!)

4.2.5Wrap hemp thread lead oil or PTFE tape around the upper thread of the installation component, and then tighten the ball valve with the sealing and locking mechanism on top.

4.2.6Slowly insert the detection rod from above and tighten the locking nut slightly. Press down on the insertion rod and measure that L2 is the same size as the L2 recorded in 4.1.2. The installation is complete.

4.2 Installation - Remove

4.2.1First, loosen the three fastening screws on the side of the locking nut, and then retract the locking nut 1-2 times to loosen the sealing pressure ring for easy removal of the insertion rod.

4.2.2Lift the handle up and lift the insertion rod about 250mm, then close the ball valve to remove the insertion rod.

5Adjustment

5.1 Insertion depth

5.1.1When selecting the electrode to be inserted at the average flow velocity point, the average flow velocity point under turbulent flow conditions in the pipeline is approximately at a distance of H1=0.25D from the pipe wall (D: pipe inner diameter)

Press the handle with your hand to insert the rod back into the H1 depth of the pipeline. (At this point, L2=original L2-H1)

5.1.2After confirming that the insertion depth is correct, rotate the handle to make its connection parallel to the centerline of the pipeline. At this point, the connection between the two electrodes will be perpendicular to the centerline of the pipeline, that is, the connection between the electrodes and the flow rate will be perpendicular.

5.1.3After adjustment, tighten the locking nut with force first, and then tighten the three locking screws separately. Their function is to ensure that the insertion rod is not pushed out by the pressure inside the tube, and to ensure that the insertion rod does not vibrate.

(Note: When tightening the first two screws, do not apply any more force as long as they come into contact with the insertion rod. Just tighten the third screw as tightly as possible.)

5.1.4When the electrode is inserted into the center of the pipeline (here is the maximum flow velocity!), the depth of the downward pressure at this time is H=0.5D.

Other jobs are the same as above.

5.1.5Loosen the fastening screws under the junction box, rotate the junction box to the desired position, and tighten the fastening screws. The adjustment is completed.

6Wiring diagram

Two RVVP type dual core single shielded cables are used to connect the sensor and the conversion display,

Wiring identification:

SIG1 SIG2 -------signal

CD1 CD2---------excitation

SIGCND-------------Ground

7, Use

7.1 Composition of plug-in electromagnetic flow meter: The plug-in electromagnetic flow sensor must be paired with an electromagnetic flow conversion display to form an electromagnetic flow meter in order to achieve and complete flow measurement tasks.

When users order plug-in electromagnetic flow sensors from our company, they should also order electromagnetic flow converters together.

7.2 Due to the fact that the plug-in electromagnetic flow sensor can only be installed in a fixed water flow pipeline when it leaves the factory (our company has an inner diameter of D)₀=A 400mm pipeline is used for flow accuracy verification, while the user pipeline may not be the same, so there is a question of how to determine the upper limit of flow. To this end, users are requested to first understand the following table - several commonly used pipeline inner diameters, average flow velocities (m/s), and volumetric flow rates (m/s)³/h) The comparison table.

DN（mm）	0.5（m/s）	1.0（m/s）	1.5（m/s）	2.0（m/s）	2.5（m/s）	3.0（m/s）
300	127.2	254.4	381.6	508.8	636.0	763.2
350	173.1	346.2	519.3	692.4	865.5	1038.6
400	226.1	452.2	678.3	904.4	1130.5	1356.6
450	286.2	572.3	858.3	1144.6	1430.8	2574.9
500	353.3	706.5	1059.8	1413.2	1766.5	2119.8
600	508.7	1017.0	1526.0	2034.0	2544.0	3052.0
700	682.4	1385.0	2047.0	2730.0	3412.0	4094.0
800	904.3	1808.0	2713.0	3617.0	4522.0	5126.0
900	1145.0	2290.0	3435.0	4580.0	5725.0	6870.0
1000	1413.0	2826.0	4239.0	5652.0	7065.0	8478.0
1200	2034.0	4068.0	6102.0	8136.0	10170.0
1400	2770.0	5540.0	8310.0	11080.0	13850.0

7.3 When the user places the electrode of the plug-in electromagnetic flow sensor at the average flow velocity of the pipeline, the user can set the flow rate, flow velocity, and other parameters correctly according to the flow parameters such as the table above, our company's factory calibration sheet, the inner diameter size of the tested pipeline, and the function and operation instructions of the electromagnetic flow converter. After that, the plug-in electromagnetic flow meter can be put into use.

7.4 When the user places the electrode of the plug-in electromagnetic flow sensor at the centerline of the pipeline, the electrode detects the maximum flow velocity V of the pipeline_maxTherefore, it is necessary toConvert maximum flow velocity to average flow velocity V_cp.The relationship between the two under turbulent flow conditions in a circular pipeline is as follows:

V_cp=K₁V_max--------（4）

In the formula; K₁<1 is related to the fluid Reynolds number R_eDThe relevant coefficients have the following values:

K₁=----------（5）

Andn=1.66lgR_eD

R_eD=354×----------（6）

In the formula: Q_m：Mass flow rate of the tested liquid (kg/h)

μ: Dynamic viscosity of the tested liquid (mPa. s)

DInner diameter of pipeline (mm)

7.5 By formula(4) It can be seen that when the user places the electrode of the plug-in electromagnetic flow sensor at the centerline of the pipeline, without correction, the flow rate (i.e. flow rate) displayed on the electromagnetic flow conversion display is 1/K higher than the correct average flow rate (i.e. flow rate)₁Twice. Users must understand and make correct adjustments when setting parameters.

The method of correction is to reduce the instrument coefficient by K₁Twice. (As previously corrected before leaving the factory)

For this reason, it is recommended that users choose to place the electrode of the plug-in electromagnetic flow sensor at the average flow velocity of the pipeline.

7.6 Regarding the blocking coefficient β

The definition of blockage coefficient β is: the depth at which the detection rod of an insertable electromagnetic flow sensor is inserted into the pipeline

The ratio of the projected area along the fluid flow direction (i.e. 0.25D or 0.5D) to the cross-sectional area of the pipeline. Namely:

β0.25D= ——————(Electrode at 0.25D, which is the average flow velocity)

Or β0.5D= ——————(Electrode at 0.5D, i.e. at the center of the pipeline)

Due to the fact that inserting this section of the rod will result in a decrease in the flow area and an increase in the average flow velocity, it should be corrected according to the magnitude of the β value when applied. There is information and experimental evidence that when β ≤ 0.03, no correction is required and there is no discernible impact on measurement accuracy.

DN300When β0.25D= 0.050 DN350When β0.25D= 0.043

DN400When β0.25D= 0.037 DN450When β0.25D= 0.033

DN500When β0.25D= 0.030 DN600When β0.25D= 0.020

So, in this case, only modifications need to be made when applied to DN300, DN350, DN400, and DN450 pipelines. DN400 is our company's factory calibrated pipeline, and the actual modifications have been made.

After calculation, when DN=600mm, β0.5= 0.049 If it is greater than 0.015, it must be corrected. The correction method is also to adjust the instrument coefficient at the time of factory production. To eliminate this correction and shorten the length of the insertion rod, we recommend placing the electrode at the average flow velocity of the pipeline.

This is another reason why we hope users can choose to place the electrode of the plug-in electromagnetic flow sensor at the average flow velocity of the pipeline..

8Supply completeness and quality assurance

8.1 The completeness of supply

8.1.1product

Plug in electromagnetic flow sensor -1 unit

RVVPDouble core shielded cable -20 meters (10 meters for signal line and 10 meters for excitation line)

(Additional orders can be placed if insufficient)

The user shall bring their own or separately order one electromagnetic flow conversion display from the company.

8.1.2Accompanying documents

Installation and Use Manual for Plug in Electromagnetic Flow Sensor -1 book

Electromagnetic flowmeter installation and use manual -1 book

(When the user orders our company's electromagnetic flow conversion display)

1 copy of water flow verification form

Certificate of conformity -1 copy

Packing list -1 copy

8.2 quality assurance

All products supplied by our company are covered by a three guarantee policy, which means that within 12 months from the date of shipment, if the instrument cannot function properly due to poor product manufacturing or non-standard components, our company is responsible for free repair, replacement of parts, components, or even the entire machine.

For our company's products that exceed the warranty period, paid lifetime maintenance is implemented.

9Transportation, acceptance, and storage

9.1 Transportation and Receipt

The plug-in electromagnetic flow sensors and electromagnetic flow conversion displays supplied by our company are packaged in wooden boxes that are moisture-proof and shockproof, and shipped by railway or road.

When receiving the goods, the user first checks whether the packaging box is intact and undamaged. If any damage is found, the user should negotiate with the carrier and contact our company for compensation and processing.

9.2 check and accept

After receiving the intact instrument packaging box, the user should immediately open it for inspection and acceptance Check the instruments inside the packaging boxCheck if the random files match the packing list, and contact our company promptly if there are any issues.

9.3storage

Users should restore the original packaging state after inspecting the goods and documents. Instruments that are temporarily not installed or have undergone maintenance should be stored indoors with the following conditions:

Rainproof and moisture-proof; Low mechanical vibration; Temperature range: -20 to+60 ℃, relative humidity not exceeding 80%.

10Ordering Notice

Users who order plug-in electromagnetic flow sensors from our company should specify:

1Pipe inner diameter size or pipe specification: outer diameter x wall thickness

2Pipeline material (if cast iron or non-metal, installation components should be designed and configured separately)

3Pressure and temperature inside the pipeline

4Name and cleanliness of the tested fluid, as well as its level of corrosiveness

5Would you like to order an electromagnetic flow conversion display together

6Additional cable length ordered