McCrometer FPI Mag 394 Bedienungsanleitung

30120-48 Rev. 2.6

August 30, 2019

COMPONENT

NSF/ANSI/CAN 61

NSF/ANSI 372

Full Prole Insertion

Electromagnetic Flow Meter

Models 394 and 395

Installation, Operation and

Maintenance Manual

Standard Model

For use in non-hazardous locations

HL Model

For use in hazardous locations:

• Class I, Division 2, Groups A-D, T5

• Class I, Zone 2 IIC T5

30120-48 Rev. 2.6 | 30AUG2019

Page ii

Contents

SAFETY ....................................................................................1

Safety Symbols .......................................................................1

Safety Warnings ......................................................................1

1.0 UNPACKING AND VERIFYING COMPONENTS ...........................................2

1.1 Unpack the Shipping Box and Verify Contents......................................2

1.2 Verify Serial Numbers ............................................................3

1.3 Verify Information On Cable Tags..................................................3

1.4 Tools Required for Installation ....................................................4

2.0 SENSOR PROBE INSTALLATION ........................................................4

STEP 1: Names of sensor components ..................................................5

STEP 2: Detach the cable quick connects ................................................6

STEP 3: Verify sensor installation location - upstream and downstream straight-pipe run

recommendations................................................................6

STEP 4: Verify sucient installation clearance from obstructions .........................8

STEP 5: Installing the pipe valve........................................................9

STEP 6: Ensure sensor will be installed perpendicular to the pipe ........................10

STEP 7: OPTIONAL STEP: Disassemble the compression seal - For installation of large

sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

STEP 8: Connecting the sensor onto pipe valve .........................................11

STEP 9: OPTIONAL STEP: Reassemble the sensor compression seal ......................11

STEP 10: Insert the sensor probe into the pipe .........................................12

STEP 11: Apply a compression load to the sensor .......................................14

STEP 12: Install the retaining rods .....................................................15

STEP 13: Attaching the ground wire ...................................................16

3.0 SENSOR REMOVAL...................................................................16

4.0 ELECTRONICS INSTALLATION ........................................................17

5.0 MAINTENANCE ......................................................................17

6.0 SPECIFICATIONS.....................................................................18

7.0 REPLACEMENT PARTS................................................................20

8.0 RETURNING A UNIT FOR REPAIR ......................................................21

WARRANTY STATEMENT ...................................................................22

30120-48 Rev. 2.6 | 30AUG2019

Page 1

Safety

Safety Warnings

When installing, operating, and maintaining McCrometer equipment where hazards may be present, you must protect

yourself by wearing Personal Protective Equipment (PPE) and be trained to enter conned spaces. Examples of conned

spaces are manholes, pumping stations, pipelines, pits, septic tanks, sewage digesters, vaults, degreasers, storage tanks,

boilers, and furnaces.

You must follow all state and local laws, as well as Occupational Safety and Health Administration (OSHA) regulations

concerning Personal Protective Equipment, conned-space entry, and exposure to bloodborne pathogens. Specic

requirements can be found in the OSHA section of the Code of Federal Regulations: 29 CFR, 1910.132 - 1910.140, Personal

Protective Equipment; CFR Title 29, Part 1910.146, Permit-Required Conned-Spaces; and 29 CFR, 1910.1030, Bloodborne

Pathogens.

SAFETY

Safety Symbols

Throughout this manual are safety warning and caution information boxes. Each warning and caution box will be identied

by a large symbol indicating the type of information contained in the box. The symbols are explained below:

This symbol indicates important safety information. Failure to follow the instructions can

result in serious injury or death.

This symbol indicates important information. Failure to follow the instructions can result in

permanent damage to the meter or installation site.

WARNING!

Incorrect installation or removal of FPI Mag meters can result in serious injury or death. Read the instructions

in this manual on the proper procedures carefully.

WARNING!

Never enter a conned space without testing the air at the top, middle, and bottom of the space. The air may

be toxic, oxygen decient, or explosive. Do not trust your senses to determine if the air is safe. You cannot see or

smell many toxic gases.

WARNING!

Never enter a conned space without the proper safety equipment. You may need a respirator, gas detector,

tripod, lifeline, and other safety equipment.

WARNING!

Pressurized pipes should only be hot tapped, cut, or drilled by qualied personnel. If possible, depressurize

and drain the pipe before attempting any installation.

WARNING!

Carefully read all safety warning tags attached to the meter.

WARNING!

Never enter a conned space without standby/rescue personnel within earshot. Standby/rescue personnel

must know what action to take in case of an emergency.

30120-48 Rev. 2.6 | 30AUG2019

Page 2

Unpacking and Verifying Components

1.0 UNPACKING AND VERIFYING COMPONENTS

The FPI Mag® (Full Prole Insertion) ow meter provides accurate ow measurement for full-pipe clean water applications.

The electromagnetic sensor automatically senses and corrects for shifting velocity in the pipe by constantly obtaining an

area weighted mean velocity. Model 394 is a forward and reverse ow measurement sensor, and the 395 is a forward only

ow measurement sensor. The instrument has all of the features needed to suit a wide variety of applications.

The ow meter is comprised of the innovative FPI Mag sensor (item #1 below) and a converter (item #4 below). For converter

installation instructions, see the manual provided for the converter purchased with your system.

The sensor is easily installed without service interruption, and requires no site calibration. Installation without service

interruption can be done only when adhering to safe hot-tapping procedures, or in locations already tted with an

appropriate full port ball valve, corporation stop or gate valve.

1.1 Unpack the Shipping Box and Verify Contents

Upon receiving the meter, unpack the contents of the shipping box and verify that the items in Figura 1 are included.

NOTE: If any of the above-listed items are not present, contact the factory before continuing with installation.

Item # Qty. Description

1 2 Long threaded insertion rods

2 1 FPI Mag Sensor

3 2

Cables with Quick-Connects

(Compression cable glands are

available as an option)

4 1 FPI Mag Installation Operation and

Maintenance Manual

5 1 Converter Installation Operation and

maintenance Manual

6 2 9/16" or 3/4" reversible ratchet

wrench

7 1 Pipe thread sealant

8 8 Hex nut (3/8" or 1/2")

9 4 Locking cotter pin

10 1 Power cord (8', 115 VAC)

11 2 Protective cap for retaining rods

12 2 Short threaded retaining rods

13 1 Converter

14 1 Stainless Steel ball valve & SS nipple

15 1 Calibration Certicate

Figura 1. Shipping Box Contents

4-10

Note: Do not discard the protective end caps (item 11). They will

be needed when the sensor is fully installed. See STEP 12.

30120-48 Rev. 2.6 | 30AUG2019

Page 3

Unpacking and Verifying Components

The tag on the side of the converter has the Converter Model Number, the Converter Serial Number and the Meter Serial

Number. An example is shown below as Figura 2.

Figura 2. Meter Serial Number Tag

Figura 3. Converter Serial Number Tag

IMPORTANT: Verify the meter serial numbers on both the converter and sensor match. If the Meter Serial Numbers

do not match, contact the factory before continuing with the installation.

1.2 Verify Serial Numbers

The FPI Mag ow meter is comprised of two primary components: the sensor and the converter. The converter and sensor

are supplied as a custom calibrated matched system. Verify the system serial numbers on both the converter and sensor

match. This will ensure a properly calibrated system.

The Meter Serial Number is located on the side of the sensor body on a silver label. An example is shown below as Figura 1.

1.3 Verify Information On Cable Tags

The converter cable has two tags located near where the cable enters

the converter as shown in Figura 3. Verify the following information is

consistent with the specications provided at the time of order:

Figura 4. Cables with Cable Tags

Tag 1

Meter Serial Number

Pipe I.D. (millimeters)

KA Factor

Tag 2

Pipe I.D. (inches)

Total Sensor Length

Total Cable Length

Cable Tags

Converter Model Number

Converter Serial Number

Meter Serial Number

30120-48 Rev. 2.6 | 30AUG2019

Page 4

Sensor Probe Installation

1.4 Tools Required for Installation

IMPORTANT

It is recommended that the sensor insertion tool be used for easier and faster installation. See STEP 10.

IMPORTANT

This instrument shall only be implemented as permanently installed equipment.

2 - 9/16" or 3/4" reversible ratchet

wrenches. (Size is dependent

on the size of the retaining rods

supplied with the sensor and

determined at the time of order.)

Tools recommended for installation:

1 - pipe wrench

capable of a 4" span

1 - 7/16" wrench

or crescent wrench

1 - Sensor

insertion tool

3/8" Part Number 75031 for TSL

< 72" and pressure < 200 psi

1/2" Part Number 75032) for TSL

> 72" or pressure > 200 psi

Tools provided:

Read the entire manual before installing the FPI Mag sensor.

2.0 SENSOR PROBE INSTALLATION

STEP 1: Names of sensor components

STEP 2: Detach the cable quick connects

STEP 3: Verify sensor installation location - upstream and

downstream straight-pipe run recommendations

STEP 4: Verify sucient installation clearance from

obstructions

STEP 5: Installing the pipe valve

STEP 6: Ensure sensor will be installed perpendicular to the

pipe

STEP 7: OPTIONAL STEP: Disassemble the compression seal

- For installation of large sensors

STEP 8: Connecting the sensor onto pipe valve

STEP9: OPTIONAL STEP: Reassemblethe sensor compression

seal

STEP 10: Insert the sensor probe into the pipe

STEP 11: Apply a compression load to the sensor

STEP 12: Install the retaining rods

STEP 13: Attaching the ground wire

Due to size and pressure requirements determined at the time of order, certain FPI Mag sensors are equipped with more

robust 1/2" threaded rods, a heavy spring, a larger top plate and a compression assembly designed to accept the larger

insertion rods. For these installations, replace all references to 3/8" rods and nuts with 1/2". The standard sensor size is

1.25". In some smaller applications the FPI Mag may use the smaller 0.75" sensor.

30120-48 Rev. 2.6 | 30AUG2019

Page 5

Sensor Probe Installation

STEP 1: Names of sensor components

This manual refers to the part names of the sensor. It is important to be familiar with the parts and their names as shown

below in Figura 5 when following the installation instructions. For a full list of replaceable parts with part numbers, see

Section 7.0.

Figura 5. Sensor Parts

Captive nut, bearing

and bearing retainer

Top plate

Set screw

Sensor assembly

Insertion rods

Retaining rods

Compression

seal assembly

Locking cotter pin

Protective caps

2” stainless steel

full port ball valve

IMPORTANT!

Do not disassemble the

sensor body. Removal of

the sensor body screws

will VOID the warranty.

Top view of

top plate

30120-48 Rev. 2.6 | 30AUG2019

Page 6

Sensor Probe Installation

STEP 2: Detach the cable quick connects

The sensor cable is tted with an IP68 rated Quick Connect tting at the sensor connection. For ease of installation, remove

the cable from the sensor and set aside. Compression gland seals are available as an option instead of the Quick Connect

cable ttings. (Figura 6)

IMPORTANT: When the Quick-Connect cable connection is not attached to the sensor, ensure that the threaded

caps are attached to the sensor connection and the cable connection to keep the wire connectors free of dirt and

corrosion. When the cable is connected to the sensor, connect the end caps together to keep their interior free

from dirt and corrosion.

Quick Connect Cables Fittings With End Caps Optional Compression Gland

Cable Fittings

STEP 3: Verify sensor installation location - upstream and downstream straight-pipe run recommendations

Figura 6. Sensor Cable Fittings

Flow disturbers such as partially open valves cause ow disturbances that can adversely aect ow meter accuracy. The

table below provides suggestions for the placement of the FPI Mag sensor upstream and downstream of common ow

disturbers to meet specication accuracy. The upstream and downstream straight-pipe recommendations are conservative,

based on research completed in the McCrometer NIST traceable calibration facility. In many cases, the installation distances

suggested below can be shortened depending on ow conditions and piping layout.

Upstream and Downstream Straight Pipe Run Recommendations

Flow

Disturbance Condition Upstream Downstream Notes

Buttery

Valve

100% Open 2D 1D Meter should be installed perpendicular to the axis of

rotation of the valve - See Figura 8

Non-Actuated

Control Valve 5D 1D

For Buttery Valves that remain in a constant position

between 50% to 100% open during operation. Meter

should be installed perpendicular to the axis of

rotation of the valve - See Figura 8

Actuating Control

Valve

20D; See

Note and

Figura 7

2D Recommended to install the sensor 2D upstream of

the Automated Control Valves

30120-48 Rev. 2.6 | 30AUG2019

Page 7

Sensor Probe Installation

Flow

Disturbance Condition Upstream Downstream Notes

Gate Valves

100% Open 0D 0D

< 100% Open

20D; See

Note and

Figura 7

2D Recommended to install the sensor 1D upstream of

the Gate Valves

Single 90

Degree

Elbows and

"T" Fittings

Sensor In Plane

with the Elbow -

See Figura 9

2D Max;

See Note 1D

It is recommended that the sensor be installed

as close to the elbow as possible, no further than

2D downstream. Otherwise the recommended

upstream piping shall be 7D.

Sensor

Perpendicular to

plane of Elbow

7D 2D None

Single 45

Degree

Elbow or

pipe bend

less than 45

degrees

Sensor In Plane

with the Elbow -

See Figura 9

1D 1D None

Sensor

Perpendicular to

plane of Elbow

5D 2D None

Double

Elbows In

Plane

Sensor In Plane

with the Elbows-

See Figura 9

2D Max;

See Note 1D

It is recommended that the sensor be installed

as close to the elbow as possible, no further than

2D downstream. Otherwise the recommended

upstream piping shall be 7D.

Sensor

Perpendicular to

plane of Elbows

7D 2D None

Double

Elbows Out

of Plane

Sensor In plane

with last elbow 7D 2D None

Reduced and

Increased

Inlets to the

Metering

Section

ID at Metering

Point up to 20%

Greater than ID of

upstream pipe

5D 1D Concentric reduction recommended. Example: Meter

Section 12" Pipe, upstream section 10" Pipe

ID at Metering

Point up to 50%

Less than ID of

upstream pipe

0D 0D Concentric reduction recommended. Example: Meter

Section 10" Pipe, upstream section 12" Pipe

Open

Discharge

Discharge of

pipe is vented to

atmosphere

Not

Applicable 2D Full Pipe Required

Pump

Discharge

Single Pump 5D 2D Recommend putting sensor on suction side of pump

where possible.

Multiple Pump

on Common

Discharge Line

20D; See

Note 2D Recommend putting sensor on suction side of pump

where possible.

Filter

Discharge

Standard Inline

Filter 5D 2D None

Note: The table above is not inclusive of each possible installation scenario for the McCrometer FPI Mag. For installations not included in

the table, the McCrometer Applications Team is available to review cases and make a determination as to the viability of the installation.

Please feel free to contact us with any questions or concerns.

30120-48 Rev. 2.6 | 30AUG2019

Page 8

Sensor Probe Installation

Figura 10. Sensor Clearance Distance

Figura 9. FPI Installed in Place with Elbow

Figura 7. FPI Mag Installation Orientation With A Gate Valve Or Elbow

Rotational axis of a buttery valve

90° 90°

Buttery Valve

FLOW

VALVE

20D UPSTREAM

FPI

FLOW

VALVEFPI

1D DOWN-

STREAM

FLOW

VALVE

20D UPSTREAM

FPI

FLOW

VALVEFPI

1D DOWN-

STREAM

FLOW

VALVE

20D UPSTREAM

FPI

FLOW

VALVEFPI

1D DOWN-

STREAM

Install the FPI Mag

perpendicular to the

rotational axis of a

buttery valve

STEP 4: Verify sucient installation clearance from obstructions

The sensor installation hardware will protrude from the pipe during installation and when installed requiring sucient

clearance (distance H, the required installation clearance, in Figura 10 below) from any obstruction. This distance accounts

for the length of the sensor, the distance from the outer pipe wall to the top of the valve plus: 18" is recommended; 12" is

the minimum.

Line Size

(Inches)

Distance

4" 51"

6" 51"

8" 55"

10" 55"

12" 59"

14" 59"

16" 59"

18" 63"

20" 63"

22" 67"

Line Size

(Inches)

Distance

24" 67"

30" 71.25"

36" 77.25"

42" 83.25"

48" 89.25"

54" 95.25"

60" 101.25"

66" 107.25"

72" 113.25"

78"-138" Call

Factory

Line size

Not to scale

Obstruction

Figura 8. FPI Mag Installation Orientation

With A Buttery Valve

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