Azbil MGR11A Electromagnetic Flowmeter User’s Manual
Below you will find brief information for Electromagnetic Flowmeter MGR11A. This is a flowmeter for applications incorporated in a filling machine. It has a fast response and is applicable to applications with complicated piping. It features a built-in converter and is designed for use in filling machines. This model offers a range of up to 300 mL/s and can be used for cleaning and sterilization processes, making it suitable for a variety of industrial applications.
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CM2-MGR200-2001
Integral style electromagnetic flowmeter for filling machines
Model: MGR11A
User’s Manual
NOTICE
© 2009-2012 Azbil Corporation All Rights Reserved.
While the information in this manual is presented in good faith and believed to be accurate, Azbil Corporation disclaims any implied warranty of merchantability or fitness for a particular purpose and makes no express warranty except as may be stated in its written agreement with and for its customer.
In no event shall Azbil Corporation be liable to anyone for any indirect, special or consequential damages. This information and specifications in this document are subject to change without notice.
Table of Contents
Chapter 1 :Introduction
Chapter 2 :Flowmeter installation
Chapter 3 :Electric wiring
Chapter 4 :Converter settings
Table of Contents
Chapter 5 :Preliminary preparation for flow rate measurement
Chapter 6 :Recommended replacement period
Chapter 7 :Troubleshooting
7.1 :Master/slave converter failure ............................................................................ 7-1
List of Figure
LED indication when the adjustment is completed successfully ............................... 5-1
List of Table
Chapter 1 : Introduction
Overview
This electromagnetic flowmeter for integrated filling machines is a flowmeter for applications incorporated in a filling machine. It has a fast response and is applicable to applications with complicated piping.
1.1 : Packing and, confirmation and storage of the product
Unpacking
This product is a precision machine. Handle the flowmeter with care when unpacking to prevent an accident and damage. Confirm that the following items are included in the package.
• Flowmeter body
• Gasket and, when selected, ferrule
Confirming the specification
The specification is described on the Name plate of the flowmeter. Refer to Appendix
A "Standard Specification, Model Number and Appearance of this Product" to check that the specification is correct.
• Basic model No.
• Diameter
• Gasket type
• Presence or absence of gasket and ferrule
Inquiry
If you have any questions about the specification, contact the azbil Group. When you contact us, please have your MODEL NO. and PRODUCT NO. ready.
Precautions for storage
When you store the product in an unused state, observe the following points.
• Keep the product in a vibration- and shock-free indoor place at room temperature and normal humidity.
• Store the product without unpacking.
When you store the product after use, follow the steps below.
(1) Tighten the cover of the flowmeter body to keep out humidity.
Model MGR11A - Integral style electromagnetic flowmeter for filling machines 1-1
Azbil Corporation
(2) Pack the product as before it was unpacked.
(3) Keep the product in a vibration- and shock-free indoor place at room temperature and normal humidity.
1.2 : Safety precautions
Overview
For safe use of this product, be sure to install and operate the flowmeter properly and perform maintenance adequately. Read the safety precautions in this manual carefully before installing and operating the flowmeter, and performing maintenance.
Precautions
The following symbols are used in this manual to ensure user safety.
WARNING
This symbol is used to warn of hazards where failure to observe a safety instruction may result in death or serious injury.
CAUTION
This symbol is used to warn of hazards where failure to observe a safety instruction may result in injury or physical damage.
1.3 : CE mark
Overview
This product conforms to CE mark standard. The declaration of conformity is shown below.
Declaration of conformity
The declaration of conformity consists of two documents.
Table 1
Name
CE Conformity
Supplement
Description
Describes compliant items regarding EMC Directive/
Standard and LV Directive that this product meets.
1-2 Model MGR11A - Integral style electromagnetic flowmeter for filling machines
Azbil Corporation
Azbil Corporation
MagneW3000 Hyper Electromagnetic Flowmeter
CE Conformity Supplement
CE CONFORMITY:
This product is in conformity with the protection requirements of the following
European Council Directive:
2004/108/EC,
the EMC Directive. Conformity of this product with any other ìCE Markî Directive(s) shall not be assumed.
EMC Directive/Standard
ELECTROMAGNETIC COMPATIBILITY:2004/108/EC,
EMC Directive
EMISSIONS:EN61326-1:2006, Gr.1 Class A,
Electrical equipment for measurement, control and laboratory use
EN 55011:2007 /A2:2007, Gr.1, Class A,
Industrial Control
Equipment,
Radiated electromagnetic disturbances 30MHz -1000MHz,
IMMUNITY: EN61326-1:2006,
Electrical equipment for measurement, control and laboratory use,
EN 61326-2-3
:2006,
Particular requirements
PC Conformity
30MHz-230MHz quasi-peak limit 40dB(uV/m) at 10m
230MHz-1000MHz quasi-peak limit 47dB(uV/m) at 10m
PERFORMANCE:
Unless otherwise noted, the performance of this product, at the specified levels of electromagnetic interference, is within the specifications for performance Under Rated
Conditions,î
Notes
IEC 61000-4-2:1995+A1:1998+A2:2001
, ESD,
Electrostatic Discharge
B
B
4 kV Contact
8kV Air
IEC 61000-4-3:2006
, Radio-frequency electromagnetic field, amplitude modulated 80 –2700 MHz
IEC 61000-4-4:2004
, Electrical Fast Transients/Burst
IEC 61000-4-5:2006
,Surge
B
10 V/m (80 –1000 MHz)
3V/m (1.0 –2.0 GHz)
1V/m (2.0 –2.7 GHz)
± 2 kV DC Power
±
1 kV I/O signal/control
B
± 1kV Line to line :Power Lines
± 2kV Line to ground :Power Lines
±
1kV Line to ground: I/O signal/control Lines
A 3V
1
IEC 61000-4-6:2007
, Conducted Radio-frequency, 150
KHz - 80 MHz
IEC 61000-4-8:1993+A1:2001
, Power frequency magnetic field
A 30 A/m 50Hz
NOTES:
PC = Performance Criteria
1. I/O signal/control Lines was not tested in accordance with EN61326-1 Table 2 NOTE (c). The equipment has signal lines less than 30 m.
Performance Criteria:
Immunity includes the tests and severity levels specified in EN 61326-1-2006 and
EN 61326-2-3-2006.
Azbil Corporation Proprietary
Model MGR11A - Integral style electromagnetic flowmeter for filling machines 1-3
MEMO
Chapter 2 : Flowmeter installation
2.1 : Ambient environment
Install the flowmeter in a place where the ambient temperature is between -5 and
50°C.
CAUTION
Do not use the flowmeter in a constantly high temperature state. Doing so may affect the flowmeter life. It is recommended to use this product between 20 and
25°C.Install the flowmeter to a low-vibration place (less than 500 Hz 4.9 m/s
2
).
Failure to do so may cause damage to the detector or instrument.
2.2 : Pipe connection
(1) Use ISO clamps for the connection. Use clamps for 1S clamp.
(2) The flow direction mark arrow that is set on the case of the detector section indicates the direction in which the fluid flows. Match the direction of the fluid flow and the direction of the arrow. Do not weld pipes after installing the flowmeter.
(3) Install the flowmeter so that the flow channel of the detector section is set at a position where it is filled with fluid.
(4) Ensure straight pipe sections for the upstream side and downstream side in the installation site.
Upstream side
Downstream side
For detector with 8 mm diameter
Ensure 15D or greater (Ensure a straight pipe section of 120 mm or more from the edge of the detector section upstream side, and inside diameter 8 mm ± 0.2
mm.). Use a straight pipe whose diameter is greater than 8 mm for upstream side of 15D.
Ensure 2D or greater (Ensure a straight pipe section of 16 mm or more from the edge of the detector section upstream side, and inside diameter 8 mm ± 0.2
mm.).
Upstream side
Downstream side
For detector with 15 mm diameter
Ensure 15D or greater (Ensure a straight pipe section of 180 mm or more from the edge of the detector section upstream side, and inside diameter 15 mm ±
0.2 mm.). Use a straight pipe whose diameter is greater than 15 mm for upstream side of 15D.
Ensure 2D or greater (Ensure a straight pipe section of 16 mm or more from the edge of the detector section upstream side, and inside diameter 8 mm ± 0.2
mm.).Be sure to ensure the required straight pipe length for the upstream side.
Failure to do so may affect the repeatability.
If an plastic pipe such as a Teflon tube is used for piping of the upstream side, ensure the straight pipe length of 20D or greater between the plastic pipe and the flowmeter.
Model MGR11A - Integral style electromagnetic flowmeter for filling machines 2-1
Flowmeter installation Azbil Corporation
(5) As a pipe connected to the detector, use a pipe of 8 mm ± 0.2 mm for models with
8 mm diameter and a pipe of 15 mm ± 0.2 mm for models with 15 mm diameter.
~Note
Note that if the piping of the upstream side length is less than 15D, the repeatability of filling amount will be affected.
2.3 : Gasket
CAUTION
Be careful not to allow the gaskets to protrude into the flow channel. Failure to do so may affect the repeatability of the filling amount. Do not tighten the clamps too much. Doing so may shorten the service life of and damage the gasket.
2.3.1: Tightening the clamp
Adjust the tightening force of the clamp while checking that the gasket is not protruding into the inside diameter.
Figure 2-1 Detector placement
Ferrule dimensions (unit: mm)
2.3.2: Replacing the gasket
Gaskets may be deformed and tarnished by the effect of CIP (cleaning in place) and
SIP (sterilizing in place) with some differences depending on the material (EPDM and
Kalrez (perfluoroelastomer)). It is recommended to check and change the gasket periodically.
2-2 Model MGR11A - Integral style electromagnetic flowmeter for filling machines
Azbil Corporation
2.3.3: Selecting the gasket
Flowmeter installation
EPDM and Kalrez (perfluoroelastomer) are available as optional materials for the gasket. Select one of them in accordance with the following conditions.
EPDM gasket:
Used for cleaning at a temperature under 120°C. EPDM tends to be less resistant than
Kalrez to SIP. EPDM gaskets generally have better anti-corrosion characteristics than silicon gaskets for CIP. However, they may need to be changed periodically depending on the chemical agent for cleaning.
Kalrez gasket:
Used for SIP at a temperature under 150°C or for frequently-performed CIP. Kalrez gaskets are less swelling and have better anti-corrosion characteristics than silicon and
EPDM gaskets and thus can be used for longer periods.
2.4 : Support mounting
A 10 mm-deep screw hole to mount the support is provided on the case for an M6 screw. Mount the support using the support mounting screw.
CAUTION
The support serves the function of bearing the weight of the flowmeter so that the pipes are not damaged by the full weight of the flowmeter after the flowmeter is mounted with clamps. Be sure to mount the support. Use of the flowmeter without the support may cause the flowmeter to fall.
Example of support mounting
Figure 2-2 Installation drawing of support mounting
Model MGR11A - Integral style electromagnetic flowmeter for filling machines 2-3
Flowmeter installation
2.5 : Converter cover
The converter cover is fixed with four M5 hexagonal bolts.
Azbil Corporation
CAUTION
• When removing the cover for wiring or other purposes, loosen the bolts while holding the cover. Failure to do so may cause the cover to fall, thereby resulting in injury.
• When removing the cover, be careful not to let moisture or water enter the converter. Failure to do so may cause an instrument failure. When reattaching the cover, make sure that the gasket is not protruding or misaligned.
2.6 : Conduit
The conduit for electric wiring and an air purging tube has an R3/4 tapered-thread structure.
CAUTION
• Securely seal the conduit to prevent water from entering. Failure to do so may cause an instrument failure.
• Set the conduit downward so that water does not enter, and securely seal the conduit using a watertight gland. Failure to do so may affect the product life.
2-4
Conduit
Figure 2-3 Conduit structure
Model MGR11A - Integral style electromagnetic flowmeter for filling machines
Azbil Corporation
2.7 : Air purge
Flowmeter installation
Perform air purge so that the pressure inside the converter becomes higher than that of the ambient environment.
Supply air continuously as specified below.
Airflow: 400 L/h [N] or higher
Air temperature: 25°C
Recommenced air purge
Flow rate:
Temperature:
Installation:
400 L/h [N] or higher
25°C or less
Insert the air purge tube into the hole of the bracket inside the flowmeter and fix it before use.
Air purge tube hole
Tube for air purge
Figure 2-4 Mounting diagram for air purge
Model MGR11A - Integral style electromagnetic flowmeter for filling machines 2-5
Flowmeter installation Azbil Corporation
2.8 : Cleaning and sterilization temperature
SIP and CIP can be used under the following conditions. However, the flowmeter life may be shortened if cleaning is performed longer or more frequently than the time or frequency described below.
SIP (Sterilizing In Place):140°C or lower for an hour (once a day)
CIP (Cleaning In Place): 90°C or lower for an hour (once a day)
2.9 : Converter wiring
2.9.1: Wiring connection table
Terminal name Name
PULSE
OUTPUT
CLOCK
OUT
+ Pulse output
-
-
+ Synchronizing signal output
CLOCK IN + Synchronizing signal
input
POWER
24VDC
-
+ Power supply
Grounding (grounding resistance: lower than
100-ohms)
Figure 2-5 Wiring connection table
.
CAUTION
The specification of the power supply is 24 V DC ± 10%. Connecting to AC power supply may cause an instrument failure. Be sure to connect properly.
2-6 Model MGR11A - Integral style electromagnetic flowmeter for filling machines
Azbil Corporation
2.9.2: Open collector pulse output wiring
Flowmeter installation
Open collector output: (NPN type)
External power supply voltage: 24 V DC/12 V DC
Output current:
Rising and falling:
50 mA max
5 µs TYP. (DC24 V)
Be sure to ground the power supply for safety.
Backflow prevention diode
200 mA max.
Protective diode
P+
Load
PÐ +
+
This is impossible.
External power supply
DC30V max.
Figure 2-6 Wiring diagram for pulse output
Voltage
DC 24V
DC 12V
Voltage drop (closed circuit)
(HIGH voltage)
19V min
7V min
Voltage drop (open circuit)
(LOW voltage)
2.5V max
2.5V max
Model MGR11A - Integral style electromagnetic flowmeter for filling machines 2-7
Flowmeter installation
2.9.3: Master/slave function
Azbil Corporation
When more than one electromagnetic flowmeter for integrated filling machines is used simultaneously, the configuration should have a master flowmeter and multiple slave flowmeters.
The number of flowmeters (The number of valves)
1
2 or more
1
1
Master flowmeter Slave flowmeter
0
1 to 168
(1) Description of the function
The master flowmeter transmits a synchronizing signal that determines the frequency of the excitation current to the first slave flowmeter. The first slave flowmeter transmits the synchronizing signal to the second slave flowmeter. This function is used to prevent mutual interference of the magnetic field when the instrumentation for the detector section of the electromagnetic flowmeter for integrated filling machines is complicated.
(2) Function setting
Setting of master/slave function is made based on the model number at the time of delivery.
Master function: MGR11A-~ -M-~. .
Slave function: MGR11A-~ -S-~
CAUTION
Do not connect the Azbil Corporation’s flowmeter to a single filling machine together with any flowmeter made by another company. Doing so may cause interference of the magnetic field, thereby affecting the repeatability of filling amount. When using more than one flowmeter, be sure to set them in the correct master/slave configuration.
2-8 Model MGR11A - Integral style electromagnetic flowmeter for filling machines
Azbil Corporation Flowmeter installation
2.9.4: Synchronizing signal output/input wiring
Get synchronizing signal cables ready. Connect CLOCKOUT± of the master flowmeter and CLOCKIN± of the slave flowmeter with the synchronizing signal cables.
When connecting multiple flowmeters, connect CLOCKOUT± of the higher-level slave flowmeter and CLOCKIN± of the lower-level slave flowmeter. Unless all of the flowmeters are connected properly, accurate measurements of the flow rate cannot be provided.
Master flowmeter
CLOCK
OUT
CLOCK
IN
＋
＋
Slave flowmeter 1
CLOCK
OUT
CLOCK
IN
＋
＋
Slave flowmeter 2
CLOCK
OUT
＋
CLOCK
IN
＋
Figure 2-7 Wiring diagram for synchronizing signal output/input
Model MGR11A - Integral style electromagnetic flowmeter for filling machines 2-9
MEMO
Chapter 3 : Electric wiring
3.1 : End terminal processing
Process the end terminals in accordance with Figure 3-1 and Figure 3-2 .
Recommended cables: Power/bus cable: MVVS 0.5sq 4-cores
Synchronizing signal cable: OTSC[U]-VB 0.5sq 1-pair
80 5
Power cable
Bus cab
5 120
Figure 3-1 Power/bus cables
80 5
5
100
Figure 3-2 Synchronizing signal cable
3.2 : Pressure terminal crimping
Crimp a pressure terminal to the core of each cable using a specialized tool. Use pressure terminals (AIO, 5-6WH) made by PHOENIX CONTACT.
Model MGR11A - Integral style electromagnetic flowmeter for filling machines 3-1
Azbil Corporation
3.3 : Connection to the customer terminal
Wire each cable in accordance with the following wiring diagram.
Pulse PULSE OUTPUT
Synchronizing signal output CLOCK OUT
Synchronizing signal input CLOCK IN
Power supply POWER DC24 V Ground E
Figure 3-3 Wiring diagram to the customer terminal
3.4 : Fixing by wire clamps
Fix each cable using wire clamps.
(1) After bundling the cables together with binding bands, cut the surplus part of the band.
(2) Bundle together cables that were separated into parts after processing the end terminal and fix them using a wire clamp.
Pulse PULSE OUTPUT
Synchronizing signal output CLOCK OUT
Synchronizing signal input CLOCK IN
Power supply POWER DC24 V Ground E
3-2
Figure 3-4 Cable fixing position
Model MGR11A - Integral style electromagnetic flowmeter for filling machines
Chapter 4 : Converter settings
The factory default of the converter is set as instructed by the customer. If you use it in its initial settings or need to change the settings in your location, contact Azbil Corporation affiliates. It is possible to perform zero adjustment for the flowmeter alone.
4.1 : Range
The flow range of this flowmeter is fixed to 300 mL/s. It is possible to output 150% of the range correctly.
4.2 : Pulse weight
The pulse weight is fixed to 0.05 mL/P. As the range is 300 mL/s, the span frequency of 6000 Hz is output at 100% of the range.
For flow rate over the range, it is possible to output up to about 150% correctly.
4.3 : Pulse width
The pulse width is fixed to 30 µs.
30 µs
Pulse width setting Tolerance
30 + 5 µs
Pulse rise time and fall time 5 µs TYP. (with 24 V DC power)
4.4 : Dropout
The default setting is 3%.
Dropout is a function to stop the pulse output that is unrelated to the flow rate (pulse output generated by the fluctuation of flow rate near the zero point).
If a certain amount of fluid flows at a percentage of around the dropout value, the pulse output may be output and stopped repeatedly due to change in flow rate.
4.5 : DF value
The DF value is a characteristic number determined by the calibration at the factory before shipment.
Model MGR11A - Integral style electromagnetic flowmeter for filling machines 4-1
4.6 : Burnout setting
Azbil Corporation
The state of pulse output, in case a failure occurs in the self-diagnostics at power-on and thus the flow rate cannot be measured, can be determined.
LOW (default): No pulse is output.
4.7 : Burnout setting (master/slave failure)
The state of pulse output in case a master/slave failure occurs can be determined.
Don't care (default): The regular flow rate measurement is continued.
4-2 Model MGR11A - Integral style electromagnetic flowmeter for filling machines
Chapter 5 : Preliminary preparation for flow rate measurement
When the installation, electric wiring and settings of the flowmeter are completed, perform the preliminary preparation for flow rate measurement.
5.1 : Warm-up operation
Operate the equipment for at least 30 minutes after turning ON the power to warm it up. If power is turned OFF once and ON again, wait for at least 10 minutes for equipment warm-up.
CAUTION
PFA lining is used for this electromagnetic flowmeter. If the high-temperature fluid and the low-temperature fluid are switched frequently, the constant temperature inside the lining cannot be maintained. When they need to be switched frequently, ensure a 30-minute or longer warm-up time to stabilize the lining.
5.2 : Zero adjustment
(1) Fill the fluid inside of the detector and confirm that the fluid is in a resting condition.
(2) Zeroing the flowmeter. Zero adjustment is automatically performed by operating holding down the switch for over a second. Confirm that the green LED on the main board goes out for five seconds then lights up.
If the adjustment fails, the LED blinks for 20 seconds. Check the water-submersion and resting condition in the pipes and then perform zero adjustment again.
Switch on off on
LED off
1 second
1 second
Figure 5-1 LED indication when the adjustment is completed successfully
Model MGR11A - Integral style electromagnetic flowmeter for filling machines 5-1
Preliminary preparation for flow rate measurement
Azbil Corporation
1 second on
Switch off on
LED off
1 second
Blinks for 20 seconds
Figure 5-2 LED indication when the adjustment has failed
Be sure to perform zero adjustment after the pipes are mounted. Failure to do so will cause a shift of the zero point as the reference value of the range, thereby shifting the dropout value and the pulse weight value, but does not affect the repeatability.
5-2 Model MGR11A - Integral style electromagnetic flowmeter for filling machines
Chapter 6 : Recommended replacement period
The entire flowmeter: 5 years
Since the electronic components will deteriorate rapidly after the recommended replacement period, have spare parts ready.
Gaskets are supposed to be consumables. Although the rate of deterioration of gaskets varies depending on the use environment, check the condition of the gaskets as needed and change them within a year.
Name
Gasket (flow channel)
Gasket (flow case)
Material
EPDM
Kalrez
Silicon
EPDM
Diameter 8 mm
80383436-002
80383436-003
80383436-001
80383407-001
Diameter 15 mm
80382478-002
80382478-003
80382478-001
80383407-001
Model MGR11A - Integral style electromagnetic flowmeter for filling machines 6-1
Recommended replacement period
Azbil Corporation
6-2 Model MGR11A - Integral style electromagnetic flowmeter for filling machines
Chapter 7 : Troubleshooting
7.1 : Master/slave converter failure
The following table shows the types and phenomena of master/slave failure, assumed causes, and how to respond to the failures.
Master/ slave failure
Master flowmeter
Master flowmeter
Phenomena
When a synchronizing signal is input to the
CLOCKIN terminal of the master flowmeter
When a synchronizing signal is not input to the
CLOCKIN terminal of the slave flowmeter
Action of the flowmeter
The red LED on the power supply board blinks at intervals of one second and the flowmeter enters the master/slave failure state. However, it continues to function normally. *2
The red LED on the power supply board blinks at intervals of one second and the flowmeter enters the master/slave failure state. However, it automatically changes its function as a slave flowmeter. *1, 2
Assumed causes
1 Model No. mismatching
2 Improper wiring
3 Flowmeter abnormality
1 Model No. mismatching
2 Unconnected wiring or cable disconnection for synchronizing signals
3 Abnormality in the anterior master or slave flowmeter
4 Abnormality in this flowmeter
3
4
Measures
Check the power supply and wiring.
1 Check the model number and the setting of master/slave switch.
2 As the master flowmeter does not need any connection to
CLOCKIN, disconnect it.
3
Check the power supply and wiring.
1
Change the flowmeter.
Check the model number and the setting of master/slave switch.
2 As a slave flowmeter needs a connection to CLOCKIN, connect it.
Change the anterior flowmeter.
Change the flowmeter.
~Note
*1 Two master flowmeters exist and interference of the magnetic field occurs at anterior or posterior position of the flowmeter that has changed from slave to master, thereby affecting the repeatability of filling amount. Take the proper measure as soon as possible.
*2 The condition of pulse output depends on the burnout setting (master/slave failure).
Model MGR11A - Integral style electromagnetic flowmeter for filling machines 7-1
MEMO
Document Number:
Document Name:
Date:
Issued/Edited by:
CM2-MGR200-2001
Integral style electromagnetic flowmeter for filling machines
Model: MGR11A User’s Manual
1st edition: May. 2009
2nd edition: Aug. 2012
Azbil Corporation
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Key Features
- Fast Response
- Integral Design
- Suitable for Complicated Piping
- Suitable for Filling Machines
- Cleaning and Sterilization Capability
- Master/Slave Configuration
