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Electromagnetic Converter

Product Overview
 

The Electromagnetic Converter is a microprocessor-based signal transmitter engineered to process low-level electromotive force (EMF) signals from electromagnetic flow sensors. It energizes the sensor's magnetic coils, extracts flow-proportional voltage via advanced synchronous sampling, and converts the data into industry-standard analog, pulse, or digital communication outputs. Designed for panel-mount, remote wall-mount, or compact integration, this unit handles bidirectional flow measurement, empty-pipe detection, and real-time self-diagnostics without signal degradation in harsh industrial environments.

 

 
 
Measurement & Testing Principle

The device operates on Faraday's Law of Electromagnetic Induction.

 

When a conductive fluid (minimum conductivity min 5 uS/cm) flows through the magnetic field generated by the sensor coils at an average velocity v, a proportional voltage E is induced:E = k * D * B * v(where k is the meter constant, D is the pipe diameter, and B is the magnetic field strength).

 

Signal Processing Pipeline: The converter samples the low-amplitude mV signal using a dual-frequency square-wave excitation method. Low-frequency excitation eliminates electrochemical polarization noise, while high-frequency excitation ensures zero-point stability and rapid dynamic response. Analog signals pass through a high-input-impedance preamplifier (greater than 10 to the power of 8 ohms), a 24-bit Analog-to-Digital Converter (ADC), and digital filtering algorithms before microprocessor scaling.

 

Product Types & Configurations

 

 

Series EC-100 (Compact / Integral Type)

Direct-mounted onto the flow sensor neck. Best suited for accessible pipeline installations with local LCD visualization.

 

Series EC-200 (Remote Wall-Mount Type)

Separated from the sensor by up to 100 meters of signal/excitation cable. Designed for high-vibration pipelines, sub-surface manholes, or high-temperature fluid environments.

 

Series EC-300 (Hazardous Area Type)

Housed in a robust metal enclosure designed for chemically demanding or industrial process zones.

 

 

Key Features

 

Dual-Frequency Excitation: Eliminates slurry noise and electrochemical interference in heavy pulp or mining slurries.

 

High Input Impedance: 10^8 ohms preamplifier circuit prevents loading effects on low-conductivity fluid measurements.

 

Dynamic Empty-Pipe Detection: Integrated electrode impedance monitoring prevents false readings during partial pipe fill conditions.

 

Bi-Directional Measurement: Independent forward and reverse totalization with configurable pulse outputs.

 

Galvanic Isolation: Optical isolation (greater than 2000V) between power supply, signal input, and output terminals to withstand industrial surge currents.

Integrated Type Electromagnetic Converter

 

Technical Specifications

 

Parameter Category

Specification Details

Excitation Frequency

6.25 Hz, 12.5 Hz, 25 Hz (selectable based on fluid characteristics)

Measurement Accuracy

Plus or minus 0.5 percent of reading (standard), Plus or minus 0.2 percent of reading (optional high-precision calibration)

Repeatability

0.1 percent

Min. Fluid Conductivity

Min 5 uS/cm

Analog Output

4-20 mA active/passive (load resistance max 750 ohms)

Digital Outputs

Pulse / Frequency output (max 5 kHz), Alarm relay outputs (solid-state)

Communication Protocols

HART, Modbus RTU (RS485), Fieldbus options available

Power Supply

85-265 VAC (50/60 Hz) or 20-32 VDC

Enclosure Material

Die-cast aluminum alloy with corrosion-resistant polyurethane powder coating

Ingress Protection

IP65 (Integral type), IP67/IP68 (Remote transmitter housing)

Ambient Temperature

-25 C to +60 C

Operating Humidity

5 percent to 90 percent RH (non-condensing)

 

Applications

 

Municipal Water & Wastewater

Effluent monitoring, sludge flow measurement, chemical dosing control.

01

Chemical & Petrochemical

Corrosive acid/alkali transfer, reaction tank feed monitoring.

02

Mining & Mineral Processing

High-solid abrasive slurry transport in copper/gold ore processing lines.

03

Pulp & Paper

Black liquor, white liquor, and paper stock flow metering.

04

Agriculture & Irrigation

Large-scale canal and pipeline water abstraction metering.

05

 

Installation & Operating Considerations

 

Remote Type Electromagnetic Converter

Grounding Requirements

Proper grounding rings or grounding electrodes are mandatory to eliminate common-mode stray currents. The converter housing must be tied to a dedicated earth ground (max 10 ohms).

 
Integrated Type Electromagnetic Converter

Cable Selection

For remote installations (EC-200), use dual-shielded specialized cables (excitation core plus signal twisted pair) to prevent cross-talk and RF interference. Do not run signal cables parallel to high-voltage power lines.

 
Battery-Powered Electromagnetic Converter

Straight Pipe Runs

Ensure upstream min 5D and downstream min 2D straight pipe clearances relative to the sensor to maintain velocity profile symmetry.

 
Remote Type Electromagnetic Converter

Zero-Point Calibration

Perform zero adjustment only when the pipeline is completely filled with static, zero-velocity fluid and the system has reached thermal equilibrium.

 

 

 
 
Manufacturing & Quality Control
01.

SMT Assembly

Circuit boards are assembled using automated Surface Mount Technology (SMT) lines with 0402 passive component precision and automated optical inspection (AOI).

02.

Conformal Coating

PCBs receive an industrial-grade acrylic conformal coating to protect circuitry against condensation, hydrogen sulfide (H2S), and humidity.

03.

Burn-In Testing

100 percent of manufactured converters undergo a 72-hour thermal burn-in cycle at +55 C under powered operating conditions to screen out semiconductor failures.

04.

Calibration & Traceability

Each unit is calibrated on a gravimetric/master-meter water flow calibration rig, generating an individual calibration coefficient sheet.

 

Customization & OEM
Firmware Integration
Custom Modbus register maps, proprietary communication framing, and brand-labeled boot screens (LCD startup logo).
Hardware Modifications
Tailored I/O terminal layouts, custom enclosure colors (RAL standard), and specialized connector interfaces (M12 or heavy-duty industrial connectors).
Protocol Expansion
Integration of specific fieldbus modules based on regional utility demands.

 

Selection Guide
 

Determine Sensor Compatibility

Verify that the coil resistance (typically 10 to 100 ohms) and electrode signal range match the converter's input specifications.

Select Mounting Style

Choose Integral (EC-100) for standard indoor utility panels; choose Remote (EC-200) if ambient temperatures exceed +60 C, vibration exceeds 1.5g, or the sensor is submerged in a pit.

Confirm Power & Output Requirements

Match plant control architecture (e.g., 24VDC power with HART over 4-20mA, or RS485 Modbus for multi-drop PLC networks).

Environment Check

Specify appropriate enclosure protection levels if installed in harsh or outdoor exposed atmospheres.

 

 

Frequently Asked Questions

 

Q: How does the converter handle low-conductivity fluids like deionized water or pure hydrocarbons?

A: Electromagnetic flow measurement requires a minimum fluid conductivity of 5 uS/cm (or 20 uS/cm for demineralized water). If the fluid falls below this threshold, the electrodes cannot reliably pick up the induced voltage. For such applications, alternative technologies like Coriolis or ultrasonic flow meters should be evaluated instead.

Q: Can this converter match with third-party electromagnetic flow sensors from other brands?

A: Yes, provided the sensor parameters are compatible. You must manually input or program the sensor's calibration factor (calibration coefficient), electrode material, coil resistance, and nominal pipe size into the converter menu during initial setup.

Q: What causes zero-point drift during field operation, and how is it corrected?

A: Zero drift is typically caused by electrochemical contamination on the electrode surface, temperature gradients, or shifting stray currents. It can be corrected via the software menu by performing a static zero-point adjustment while ensuring the fluid inside the sensor is completely stationary.

Q: What is the maximum allowable distance between a remote converter and the sensor?

A: For standard signal and excitation cables, the maximum recommended distance is 100 meters. Exceeding this limit causes signal attenuation and phase shifts. If distances greater than 100 meters are required, pre-amplifier junction boxes or specialized low-capacitance shielded cables must be utilized.

Q: What diagnostic alerts are triggered when the pipeline is empty?

A: The converter continuously monitors the impedance between the empty-pipe detection electrode and the reference ground. When the liquid level drops below the electrode tip, the circuit resistance increases beyond the preset threshold, triggering an "Empty Pipe" warning flag on the LCD and driving the analog output to a preset fail-safe state (e.g., 0 mA or 3.6 mA).

Q: What communication protocols are natively supported for PLC and SCADA integration?

A: The unit natively supports 4-20mA with HART protocol and RS485 via Modbus RTU. Optional plug-in modules are available for fieldbus systems depending on plant architecture requirements.

Dalian Yheng Technology Co., Ltd. is one of the leading electromagnetic converter manufacturers and suppliers in China, also supports customized service. We warmly welcome you to buy high quality electromagnetic converter in stock here from our factory. Contact us for more details.

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