ABB K-MAG 10D1476 Instruction Manual
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ABB K-MAG 10D1476 Instruction Manual

Magnetic flowmeters
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INSTRUCTION MANUAL
MAGNETIC FLOWMETERS
10D1476 Design Level S
1/25 - 4 in.
K-MAG
MAGNETIC FLOWMETER
PN25009A

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  • Page 1 INSTRUCTION MANUAL MAGNETIC FLOWMETERS 10D1476 Design Level S 1/25 - 4 in.  K-MAG MAGNETIC FLOWMETER PN25009A...
  • Page 2 Some process upsets may cause injury or damage. NOTICE The information contained in this document is subject to change without notice. ABB Inc. reserves the right to make minor changes to this publication, such as company name & logos as well as other minor corrections, without necessarily changing the publication number.

  • Page 3: Table Of Contents

    10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL Table of Contents SAFETY SUMMARY ........... . . I READ FIRST .
  • Page 4 10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL 6.0 MAINTENANCE ........... 6-1 6.1 General .

  • Page 5: Safety Summary

    Some process upsets may cause injury or damage. RETURN OF EQUIPMENT All Flowmeters and/or Signal Converters being returned to ABB Inc. 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.
  • Page 6 RETOUR D’ÉQUIPEMENT. Tout débitmètre et(ou) convertisseur re- tourné à ABB Inc. pour réparation doit être exempt de toute trace de produit dangereux (acide, base, solvant, … ). Un certificat de sécurité matériel doit être joint pour tous les liquides utilisés dans le procédé.

  • Page 7: Read First

    Read these instructions before starting installation; save these instructions for future reference. Contacting the Factory... Should assistance be required with any of the company’s products, contact the following: Telephone: 24-Hour Call Center 1-800-HELP-365 E-Mail: ins.techsupport@us.abb.com...
  • Page 8 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 ABB Inc. representative to obtain the correct touch-up paint.

  • Page 9: Introduction

    10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL 1.0 INTRODUCTION 1.1 General  The Series 10D1476 K-MAG magnetic flowmeter, shown in Figure 1-1, is an electromagnetic liquid flow rate detector. The meter uses the characteristics of a conductive liquid to generate an induced signal voltage, directly proportional to flow rate, as the liquid passes internal electrodes.
  • Page 10 10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL This flowmeter can be used to meter either clean or dirty liquids. The meter may be used without regard to the heterogeneous consistency of the measured liquid and is as independent of the tendency to plug or foul as the pipeline in which it is mounted. By design, only the ceramic spool meter body and electrodes are wetted parts, and will accommodate most acids, bases, water and aqueous solutions.

  • Page 11: Model Number Breakdown

    10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL With the exception of the primary board, the associated electronics package is called the signal converter and is remotely mounted. Figure 1-2 shows the electronics compartment for the remote signal converter. The remote mounted signal converter improves performance if 1) the vibration specification is exceeded and/or 2) the process liquid temperature vs.
  • Page 12 10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL Model 10D1476S 10D1476 S H __ _ _ _Y _ _3 _A _1 _1 _ _2 Engineering Reference Design Level with 50XM Electronics Liner Material Ceramic Spool Meter Size [Inches (mm)] 1/25 1/12 1/10 5/32 (10) (15)
  • Page 13 10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL Model 10D1476S (Cont.) 10D1476 S Power Requirements Remote Converter Enclosure Classification IEC 529 IP 65, NEMA 4X Accidental Submergence, IEC 529 IP 67 30 ft. H O/48 hr. (9 m H O/48 hr.) Fluid Temperature Range up to 356 F (180 Output Current...

  • Page 14: Specifications

    10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL 1.3 Specifications Power Requirements See Section 1.2 Model Number Breakdown Power Consumption Refer to signal converter instruction manual for power input requirements; typically, 30VA. Flowmeter Characteristics Meter Size/Flow Capacity See Table 1-1 Span Factory set at specified range between extremes listed in Table 1-1;...
  • Page 15 10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL NOTE The temperature gradient between the liquid and the ceramic spool should not exceed 212 F (100 C) when increasing the temperature or 158 C) when cooling, to prevent cracking. For example, if the ceramic is at a temperature of 20 C, liquids at 120 C can be handled.
  • Page 16 10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL Materials of Construction Meter Body (Spool) Ceramic, 99.5% Alumina Electrode Assemblies (wetted) Platinum Meter Housing carbon steel, all welded construction, epoxy finish Housing End Rings 304 sst Electronics Housing die cast aluminum, epoxy finish, 316 sst attach- ment screws, 1/2 NPT conduit connections, gas- keted covers Installation Kit...

  • Page 17: Installation

    10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL 2.0 INSTALLATION 2.1 Inspection All Model 10D1476 K-MAG magnetic flowmeters are shipped in heavy duty containers. The packag- ing used for K-MAG protection is certified for air shipment by the Container Testing Laboratory. An itemized list of all items included in the shipment is attached to the shipping container.
  • Page 18 10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL [Modif.] FIGURE 2-1. OUTLINE DIMENSIONS, SIZES 1/25" THROUGH 1-1/2"...
  • Page 19 10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL [Modif.] FIGURE 2-2. OUTLINE DIMENSIONS, SIZES 2" THROUGH 4"...

  • Page 20: Location

    10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL 2.2 Location The flowmeter is suitable for either indoor or outdoor installation. When selecting the installation site, consideration should be given to the ambient and process temperature limits, as stated in Specifica- tions Section 1.3. The standard meter is rated NEMA 4X, (dust tight and watertight) and will thus stand rain and hose down.

  • Page 21: Meter Handling

    10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL 2.3.2 Meter Handling The ceramic body of the flowmeter must be protected at all times, as it can be damaged by sharp objects or cracked by sharp impact blows. If required, temporary supports may be used during meter installation.
  • Page 22 10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL FIGURE 2-3 OUTLINE DIMENSIONS, WITH SANITARY FITTINGS, SIZES 1/25" THROUGH 1-1/2"...
  • Page 23 10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL FIGURE 2-4 OUTLINE DIMENSIONS, WITH SANITARY FITTINGS, SIZES 2" THROUGH 4"...
  • Page 24 10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL FIGURE 2-5. RECOMMENDED PIPING DIAGRAM...
  • Page 25 10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL TABLE 2-1. RECOMMENDED BOLT TORQUE Meter Size ANSI CL 150 ANSI CL 300 DIN PN 40 mm (inch) DIN PN 16 BS TABLE F BS TABLE D & F 1 - 25 10 ft lb 15 ft lb 15 ft lb ⁄...

  • Page 26: Basic Mounting Procedure, Standard Coupling

    10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL FIGURE 2-7. MOUNTING DIAGRAM FOR 1- 40 mm (1/25 - 1-1/2") SIZES 2.3.4 Basic Mounting Procedure, Standard Coupling Select the following procedure applicable for the size meter supplied. 2.3.4.1 1 - 40 mm (1/25 - 1-1/2 inch) Meter Sizes Refer to Figures 2-1 and 2-6 to supplement the following procedure.

  • Page 27: 100 Mm (2 - 4 Inch) Meter Sizes

    10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL 5. Thread nuts on both ends of the four mounting studs, finger-tight. 6. To center the magnetic flowmeter with the longitudinal axis of the pipeline, press down firmly on the centering device. This will force-spread the mounting studs, thereby centering the meter body. Maintain pressure on centering device and tighten nuts of the mounting studs until nuts are suffi- ciently tight to prevent movement of meter relative to the flanges.
  • Page 28 10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL FIGURE 2-8. MOUNTING DIAGRAM FOR 50 - 100 mm (2 - 4") SIZES 2-12...

  • Page 29: Mounting Procedure, Sanitary Coupling

    10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL FIGURE 2-9. MOUNTING DIAGRAM, SANITARY FITTINGS 2.3.5 Mounting Procedure, Sanitary Coupling The magnetic flowmeter must be oriented as shown by the flow direction arrow on the meter data tag. The meter, when installed, will generally be supported by the adjacent pipeline sections. These upstream and downstream pipe sections must be fabricated of rigid piping.

  • Page 30: Grounding Procedure

    10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL 2.4 Grounding Procedure 2.4.1 General Satisfactory operation of the magnetic flowmeter system requires that careful attention be paid to proper grounding techniques. 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 insuring that the meter ground is in contact with the process liquid at both ends of the meter body.

  • Page 31: Non-Conductive Or Insulated Pipeline

    10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL 2.4.3 Non-Conductive or Insulated Pipeline For the magnetic flowmeter mounted in a non-conductive or liquid insulated pipeline (such as totally plastic pipe, ceramic lined iron pipe, or cast pipe with internal bitumastic coating), perform the grounding procedure outlined below.
  • Page 32 10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL FIGURE 2-11. GROUNDING PROCEDURE, NON-INSULATED PIPE 2-16...
  • Page 33 10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL FIGURE 2-12. GROUNDING PROCEDURE, INSULATED PIPE 2-17...

  • Page 34: Electrical Interconnection

    10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL 2.5 Electrical Interconnection The Series 10D1476S K-MAG magnetic flowmeter is furnished with a remotely mounted signal converter. Interconnection wiring is done in the customer connection box shown in Figure 2-13. For additional information and wiring details, refer to interconnection diagrams provided in the instruction manual supplied with the signal converter.

  • Page 35: Start-Up And Operation

    10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL 3.0 START-UP & OPERATION The ABB Series 10D1476 K-MAG Magnetic Flowmeter (which includes the integral or remote Signal Converter) is precision calibrated at the factory for the values stated on the instrument tags. If specific values were not specified, the meter is calibrated at some nominal maximum flow rate and for a 4-20 mA current output span.
  • Page 36 10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL E L E C T R O N I C S HOUSING (COVER REMOVED) PLUG P3 PRIMARY ZERO/ CMF BOARD ADAPTER BOARD CUSTOMER CONNECTION BOARD JUNCTION 1/2" NPT CONDUIT CONNECTION (2) FIGURE 3-3. PRIMARY MOUNTED PC ASSEMBLIES...

  • Page 37: Functional Description

    10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL 4.0 FUNCTIONAL DESCRIPTION The Magnetic Flowmeter body houses two signal electrodes and the flux producing magnet coils, as shown schematically in Figure 4-1. All primary intraconnection wiring is terminated at a printed circuit assembly located in the base of the meter housing (see Figure 3-2). The primary provides two output signals to the associated Signal Converter: •...

  • Page 38: Magnet Coil Drive Circuits

    10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL This may be expressed mathematically as: (Equation #1) = 1 BDV α where, = induced electrode voltage B = magnetic field strength D = meter pipe diameter V = liquid velocity α = dimensionless constant Thus, the metered liquid constitutes a continuous series of conductive liquid discs moving through a magnetic field.

  • Page 39: Operating Characteristics

    10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL (Equation #3) Q = γ E where: Q = volumetric flow rate A = cross-sectional area D = pipe section diameter = induced signal voltage = reference voltage B = magnetic flux density α = dimensionless constant β...

  • Page 40: Liquid Temperature

    10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL The electrode diameter is 0.15 cm (0.060") for all meter sizes except 1/25" ((0.020") and 1/12" (0.040"). For example, assuming the measured ac electrode resistance (full pipe and zero flow) is 190,000 ohms and electrode diameter is 0.15 cm, then σ...

  • Page 41: Circuit Description

    10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL 5.0 Circuit Description 5.1 Primary Signals The Magnetic Flowmeter body houses two signal electrodes and the flux producing magnet coils, as shown schematically in Figures 5-1. All primary intraconnection wiring is terminated at the CMF/ZERO pc board located in the base of the meter housing.
  • Page 42 FIGURE 5-1. SCHEMATIC for PRIMARY WIRING...
  • Page 43 10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL 5.3 Jumper Selections For remote converters, zero return and functions associated with the 50XM1000 signal converter are established by the 686B623U01 Primary Board assembly, shown in Figure 5-2. Settings are determined by movable jumpers at terminals A2 and B1 located on the lower left corner of the 686B623U01 assembly.
  • Page 44 10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL FIGURE 5-2. 686B623U01 CMF/ZERO PCB ASSEMBLY Jumpers Functions Zero return 10 kHz Pulse reverse...
  • Page 45 FIGURE 5-3. SCHEMATIC for CMF BOARD...
  • Page 46 10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL 6.0 MAINTENANCE 6.1 General Except for an occasional performance verification check, there is no required routine maintenance for the Model 10D1476. The Flowmeter body is of all welded construction. In the event a malfunction occurs in the Flowmeter body, the meter body must be replaced.
  • Page 47 10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL 6.2 System Troubleshooting If the Magnetic Flowmeter does not appear to be operating properly, the following procedure can be used as a guide to isolate the malfunctioning device to either the primary meter or the Signal Converter.
  • Page 48 10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL 3. Possible causes of erroneous flow rate indication are: • incorrect grounding • excessive noise due to a heavy slurry process or a non-homogeneous process • loose or intermittent wiring • non-full or empty meter pipe •...
  • Page 49 10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL 5) Set the Ohmmeter to its highest range (R x 10,000) and measure from wire lead M1 or MR to the meter body (case ground). The resistance reading should be infinite. If this measurement is less than 100 K ohms, the meter is defective and must be replaced.
  • Page 50 10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL 6.3.3 Flowmeter Board The Flowmeter board is located in the base of the electronics housing as shown in Figure 6-1. This pc board includes the constant meter factor/size network. The constant meter factor/size network is used to standardize the particular flowmeter;...
  • Page 51 10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL 9. After R3 has been adjusted, R2 is to be set so that the Converter output is zero. For CD-1 Converters, the Converter must be elevated on a 1 ft/sec span and R2 then set to obtain 74.3% output (+/- 0.2%).
  • Page 52 10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL 7.0 PARTS LIST TABLE 7-1. ANSI CLASS 150 GROUNDING RINGS Meter Size ABB Part Part Number Suffix (Material) inch 316 sst Hast. "C" Hast. "B" Alloy 20 Number* ⁄ ⁄ 1 - 15 800D508 800D508 ⁄...
  • Page 53 10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL FIGURE 7-1. EXPLODED VIEW, BASIC FLOWMETER PARTS...
  • Page 54 10D1476 K-MAG MAGNETIC FLOWMETER INSTRUCTION MANUAL TABLE 7-4. BASIC METER PARTS (REF: FIGURE 7-1) KEY QTY DESCRIPTION SIZE, mm PART NUMBER METER BODY:SEE NOTE 1 O-RING:Converter Base Seal 3 - 25 101A927U01 40 - 50 101A937U01 101A922U01 101A927U01 BOLT, Self Sealing 091B022U01 LOCTlTE, Type 271 145A016U02...
  • Page 55 The Company’s policy is one of continuous product improvement and the right is reserved to modify the information contained herein without notice. © 2003 ABB Inc. Printed in USA ABB Inc. ABB Instrumentation Ltd ABB Instrumentation S.p.A ABB Automation Products GmbH 125 East County Line Road Howard Road, St.

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