Promag 10/50/53 Electromagnetic Flowmeter Installation Guide

Promag 10/50/53 Electromagnetic Flowmeter Installation Guide

Proper installation of the Promag 10/50/53 series electromagnetic flowmeter is crucial for measurement accuracy and equipment lifespan. This guide covers installation location, orientation, vibration, grounding, cable length, and key installation points for different sensor models, for reference by engineering and technical personnel and procurement staff.

I. Installation Location

The installation location of the electromagnetic flowmeter directly affects measurement stability. Gas accumulation or bubbles in the measuring tube will increase measurement error, so the following locations should be avoided:

• The highest point of the pipeline, where bubbles easily accumulate.
• Above a downward-draining pipeline.

1. Pump Installation Location

Do not install the sensor on the inlet side of the pump to avoid damaging the measuring tube liner during suction. When using piston pumps, diaphragm pumps, or peristaltic pumps, a pulsating flow buffer must be installed.

2. Partially Filled Pipes

Inclined pipes in a partially filled state require a drain outlet. The empty pipe detection (EPD) function can detect whether the pipe is full or partially filled. Accumulation of solid residue should be avoided. Do not install the sensor at the lowest point of an inclined pipe; installing a drain valve is recommended.

3. Vertical Pipes

In downward pipes longer than 5 meters (16 feet), a siphon or drain valve must be installed downstream of the sensor to avoid damaging the measuring tube liner during suction. This measure can also prevent cavitation in the system caused by pressure drop.

Installation on vertical pipes (h > 5 m/16 ft):

1. Drain valve
2. Siphon

II. Installation Orientation

The optimal installation orientation helps avoid gas accumulation and residue buildup in the measuring tube. In addition, for correct measurement of certain special fluids, the following accessories can be selected:

• Electrode cleaning circuit (ECC): Used to prevent conductive medium buildup in the measuring tube, such as when measuring easily adhering fluids.
• Empty pipe detection (EPD) function: Used to detect partially filled pipes, such as when measuring degassed fluids or changing process pressure.
• Replaceable measuring electrodes: Used when measuring abrasive fluids (Promag W only).

1. Vertical Installation

The ideal installation orientation for self-draining piping systems and measurement systems using the empty pipe detection function (EPD) or open electrode detection function (OED).

2. Horizontal Installation

The measuring electrode plane must remain horizontal, which prevents short-term insulation between the two electrodes caused by bubbles. The empty pipe detection function can only work properly when the measuring tube is installed horizontally and the transmitter housing faces vertically upward. Otherwise, when the pipe is partially filled or empty, proper functioning of the empty pipe detection function cannot be guaranteed.

• EPD electrode (empty pipe detection): Not applicable to Promag H, DN2-15, 1/12'-/" .
• Measuring electrode (signal detection).
• Reference electrode (potential equalization): Not applicable to Promag H.

3. Upstream and Downstream Straight Pipe Sections

If possible, the sensor installation location should avoid pipe fittings such as valves, tees, and elbows.

4. Sensor Nameplate

The sensor nameplate contains the following information:

1. Order number/serial number
2. Calibration K-factor/zero point
3. Nominal diameter/pressure rating
4. Fluid temperature range TM: measuring tube
5. Material: liner/electrode
6. Reserved information for special products
7. Permissible ambient temperature
8. Observe device documentation
9. Additional reserved information for device version (certifications, certificates)
10. Calibration tolerance
11. Additional information (examples): EPD/MSU: empty pipe detection electrode; R/B: reference electrode
12. Protection class
13. Fluid direction

III. Vibration

If vibration is very severe, pay attention to securing the piping and sensor. Measures to prevent equipment vibration (L > 10 m/33 ft). Note: If vibration is very severe, it is recommended to install the sensor and transmitter separately.

IV. Base and Support

If the nominal diameter is DN≥350 (≥14"), install the sensor on a base with sufficient load-bearing capacity.

Note: Risk of damage! Do not use the outer frame to bear the weight of the sensor. Deformation of the outer frame may damage the excitation coils inside the sensor.

V. Potential Equalization—Grounding

Equal potential between the measured fluid and the sensor is a prerequisite for accurate measurement with an electromagnetic flowmeter. Most sensors are equipped with a standard reference electrode to ensure equipotential connection. Usually, no other measures or grounding rings are needed to ensure potential equalization. Promag L, Promag W, and Promag P reference electrode (standard).

• Promag H: No reference electrode. Potential equalization with the measured fluid is achieved through metallic process connections. For systems using plastic process connections, grounding rings must be used to achieve system potential equalization.

1. Standard Case

When using the device in grounded metal pipes, potential equalization is achieved through the grounding terminal of the transmitter.

2. Special Cases

The flowmeter is installed in ungrounded metal pipes. This connection method is also suitable for:

• When system potential equalization cannot be achieved by conventional methods
• When extremely high equalizing currents may occur

Both flanges are connected to the pipe flanges via grounding cables (copper wire, cross-sectional area of at least 6 mm² (0.0093 in²)) and grounded. Connect the transmitter or sensor junction box to a dedicated grounding terminal to achieve system potential equalization.

• DN≤300 (12'): Install the grounding cable directly on the conductive coating of the flange using flange bolts.
• DN≥350 (14"): Install the grounding cable directly on the metal bracket.

The flowmeter is installed in plastic pipes or pipes with insulating liners. This connection method is also suitable for:

• When system potential equalization cannot be achieved by conventional methods
• When extremely high equalizing currents may occur

System potential equalization is achieved through additional grounding rings. The grounding rings are connected to the grounding terminal via grounding cables (copper wire, cross-sectional area of at least 6 mm² (0.0093 in²)). When installing grounding rings, follow the requirements of the installation guide.

The flowmeter is installed in pipes with cathodic protection units. The flowmeter should be installed in equipotential pipes. Only connect the two pipe flanges via grounding cables (copper wire, cross-sectional area of at least 6 mm² (0.0093 in²)). Install the grounding cable directly on the conductive coating of the flange using flange bolts.

This connection method is also suitable for:

• The applicable specifications for equipotential installation must be observed.
• No other conductive electrical connection may exist between the pipe and the flowmeter.
• The installation materials must meet the application torque requirements.

VI. Length of Connecting Cable

When installing a remote version instrument, follow these points:

• Lay the cable fixedly in a metal shielded conduit. Movement of the cable can cause distortion of the measurement signal, especially when the conductivity of the fluid is low.
• Do not lay the cable near electrical equipment and switch cabinets.
• Ensure that the transmitter and sensor are at equal potential.
• The permissible cable length Lmax depends on the conductivity of the fluid.

Gray shaded area = permissible range; Lmax = connecting cable length (in [m]/[ft]); fluid conductivity (in μS/cm).

VII. Installation of Promag L Sensor

• The protective plates installed on the two sensor flanges (DN 50...300) are used to secure the flanges to protect the PTFE liner during transport. Therefore, these protective plates must not be removed before installing the sensor into the pipe.
• During storage of the device, the protective plates must not be removed.
• Ensure that the flange liner is not damaged or removed.

Note! Screws, nuts, and sealing rings are not included in the scope of delivery and must be provided by the customer. The sensor is installed between two pipe flanges:

• The required torque must be observed.
• If grounding rings are used, follow the installation guide supplied with the delivery.
• To comply with the technical specifications of the device, concentric installation in the measuring section is required.

Sealing Ring Installation

Observe the following instructions when installing sealing rings:

• Hard rubber liner → Additional sealing rings are always required!
• Polyurethane liner → No sealing rings required.
• For PTFE measuring tube liners, no sealing rings are required.
• For DIN flanges, use only sealing rings that comply with DIN EN 1514-1.
• Ensure that the installed sealing rings do not protrude into the pipe cross-section.

Note! Risk of short circuit! Do not use conductive sealing materials, such as graphite! A conductive layer will form on the inside of the measuring tube, short-circuiting the measurement signal.

For screw tightening torque (Promag L), refer to the table.

VIII. Installation of Promag P Sensor

Note! The protective plates installed on the two sensor flanges protect the flared PTFE, so they should only be removed before installing the sensor.

• During storage of the device, the protective plates must not be removed.
• Ensure that the flange liner is not damaged or removed.

Note! Screws, nuts, and sealing rings are not included in the scope of delivery and must be provided by the customer.

The sensor is installed between two pipe flanges:

• The required torque must be observed.
• If grounding rings are used, follow the installation guide supplied with the delivery.

Sealing Ring Installation

Observe the following instructions when installing sealing rings:

• For PFA or PTFE measuring tube liners, no sealing rings are required.
• For DIN flanges, use only sealing rings that comply with DIN EN 1514-1.
• Ensure that the installed sealing rings do not protrude into the pipe cross-section.

Note! Risk of short circuit! Do not use conductive sealing materials, such as graphite! A conductive layer will form on the inside of the measuring tube, short-circuiting the measurement signal.

For screw tightening torque (Promag P), refer to the table.

IX. Installation of Promag H Sensor

Use of Sealing Rings

When installing process connections, ensure that the relevant sealing rings are clean, dust-free, and properly centered.

Note: When using metallic process connections, the screws must be firmly tightened. The process connection together with the sensor forms a metallic connection, ensuring the specified sealing pressure.

• For plastic process connections, observe the maximum torque value for lubricated threads (7 Nm/5.2 lbf ft). A sealing ring must always be used between the process connection and the plastic mating flange.
• Sealing rings should be replaced periodically according to the application, especially when using molded sealing rings (aseptic type)! The replacement interval for sealing rings depends on the cleaning cycle, fluid temperature, and cleaning temperature. Replacement sealing rings can be ordered separately as accessories.

Use and Installation of Grounding Rings (DN 2 - 25, 1/12'- 1')

For plastic process connections (e.g., flange connections or adhesive connections), potential equalization between the sensor and the fluid must be ensured through additional grounding rings. If the grounding ring is lost, electrochemical reactions will damage the electrodes, thereby affecting sensor accuracy or causing sensor damage. The grounding ring (including sealing rings) is installed inside the process connection. The face-to-face distance is not affected.

Installing the grounding ring:

1. Loosen the four or six hex bolts (1) and remove the process connection from the sensor (4).
2. Remove the plastic ring (3) from the process connection, including the two O-ring seals (2).
3. Insert one of the O-ring seals (2) back into the groove of the process connection.
4. Place the metal grounding ring (3) into the process connection as shown.
5. Insert the second O-ring seal (2) into the groove of the grounding ring.
6. Reinstall the process connection onto the sensor. During installation, ensure that the maximum torque value for lubricated threads (7 Nm) (5.2 lbf ft) is observed.

Welding the Sensor to the Pipe (Welding Pipe Joints)

Note! Risk of damage to electronic components! Ensure that the welding equipment is not grounded through the sensor or transmitter.

1. Tack weld the process connection to secure the sensor in the pipe. Suitable welding fixtures can be ordered separately as accessories.
2. Loosen the screws on the process connection flange and remove the sensor (including sealing rings) from the pipe.
3. Weld the process connection into the pipe. Reinstall the sensor back into the pipe. During installation, ensure that the sealing rings are clean and correctly positioned.

Note!

• When properly welding on thin-walled pipes conveying food, even with sealing rings installed, they will not be damaged by heat. However, it is recommended to remove the sensor and sealing rings before welding.
• For disassembly work, it must be possible to open the pipe by approximately 8 mm (0.31 in).

X. Rotating the Transmitter Housing

When it is inconvenient for the customer to view the display head on site, the display head can be rotated.

Field-mounted aluminum housing used in non-hazardous areas

1. Loosen the fixing screws.
2. Gently rotate the transmitter housing clockwise to the stop (top of thread).
3. Rotate the transmitter housing counterclockwise (maximum 360°) to the desired position.

Rotating the field-mounted stainless steel housing for field-mounted aluminum housing used in Zone 1 or CI.I Div.1 hazardous areas

XI. Installing the Wall-Mounted Housing

1. Direct Wall Mounting

Determine that the ambient temperature does not exceed the permissible range (-20 --+60°C). Install in a shaded location, avoiding direct sunlight. Install with the cable entry facing downward.

1. Terminal compartment
2. Fixing screw M6: max.ø6.5 mm (0.25"); screw head: max.ø10.5 mm (0.4")
3. Fixing screw mounting holes on the housing

2. Column Mounting Dimension Diagram

3. Panel Mounting Dimension Diagram