ABB AquaMaster4 User manual

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ABB MEASUREMENT & ANALYTICS | OPERATING INSTRUCTION
AquaMaster4
Electromagnetic flowmeter flanged sensor
The ideal flowmeter for potable
water distribution networks,
revenue metering and irrigation
applications
Measurement made easy
Introduction
AquaMaster4 flanged sensors are a range of high
performance electromagnetic flowmeter sensors
for the measurement of electrically-conductive
fluids and are normally supplied as factory-
configured, calibrated systems.
This publication provides end-user details for the
AquaMaster4 flanged sensor range.
For more information
Further publications for AquaMaster4 are available
for free download from
http://new.abb.com/products/measurement-
products
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Harness the power
of electromagnetic
flowmeters

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AQUAMASTER4 | ELECTROMAGNETIC FLOWMETER FLANGED SENSOR | OI/FEW400/FRV-EN REV. A
Contents
1 Health & Safety ............................. 4
Document symbols ................................ 4
Safety precautions ................................ 4
Intended use ...................................... 4
Improper use...................................... 4
Potential safety hazards ............................5
FEW4 AquaMaster4 sensor – electrical .........5
Safety standards ...................................5
Waste Electrical and Electronic Equipment (WEEE) ...5
Product recycling and disposal (Europe only) ........5
Information on ROHS Directive 2011/65/EU (RoHS II) 6
Product symbols .................................. 6
2 Sensors overview ............................7
R-series | reduced bore .............................7
V-series | octagonal bore ...........................7
F-series | full bore ................................. 8
3 Product identification .......................9
Nameplate ........................................ 9
Integral sensor ...............................9
Remote sensor ...............................9
4 Transport and storage ..................... 10
Inspection ........................................10
Transport .........................................10
....................10
....................10
Storing the sensor.................................10
Storage temperature.........................10
5 Installation.................................11
General information ...............................11
Installation requirements ..........................11
Lay lengths .................................. 11
Unpacking the sensor ........................ 11
Fluid level ................................... 11
Pipeline support .............................12
Extremes of temperature ....................12
Seal materials / fluid temperatures ...........12
Pipeline forces / torque ......................12
Spillage onto the sensor......................12
Flow direction / straight pipe requirements ..13
Electrode axis ...............................13
Localized heating / welding ..................14
Environmental rating ........................14
Gasket fitting ...............................14
Cable routing................................14
Burying a sensor.............................15
Sensor separation ...........................15
Dimensions .......................................16
R-style sensor – DN 40 to DN 300 (1½ to 12 in.) 16
R-style sensor – DN 350 to DN 600 (14 to 24 in.)18
V-style sensor – DN 40 to DN 200 (1½ to 8 in.) . 20
F-style sensor – DN 250 to DN 400 (10 to 16 in.) 22
F-style sensor – DN 450 to DN 600 (18 to 24 in.)24
F-style sensor – DN 700 to DN 2400
(28 to 96 in.) .................................26
Grounding ....................................... 32
Cathodic-protected systems .................32
Connections ..................................... 33
Signal cable preparation .....................33
Signal cable connection – remote sensors .....33
Environmental protection ....................33

AQUAMASTER4 | ELECTROMAGNETIC FLOWMETER FLANGED SENSOR | OI/FEW400/FRV-EN REV. A
3
6 Commissioning ............................ 34
Safety instruction ................................ 34
Checks prior to commissioning ................... 34
7 Repair .................................... 34
Spare parts ...................................... 34
Common accessories ........................34
8 Recycling and disposal ..................... 35
Disassembly ..................................... 35
Disposal ......................................... 35
9 Specification ............................. 36
Reduced bore sensor ............................. 36
Full bore sensor .................................. 38
10 Appendix ................................. 41
Declarations of conformity.........................41

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AQUAMASTER4 | ELECTROMAGNETIC FLOWMETER FLANGED SENSOR | OI/FEW400/FRV-EN REV. A
1 Health & Safety
Document symbols
Symbols that appear in this document are explained below:
DANGER – SERIOUS DAMAGE TO HEALTH
This symbol in conjunction with the signal word
‘DANGER’ indicates an imminent electrical hazard.
Failure to observe this safety information will result in
death or severe injury.
WARNING – BODILY INJURY
This symbol in conjunction with the signal word
‘WARNING’ indicates a potential electrical hazard.
Failure to observe this safety information will result in
death or severe injury.
CAUTION – MINOR INJURIES
This symbol in conjunction with the signal word
‘CAUTION’ indicates a potentially dangerous
situation. Failure to observe this safety information
may result in minor or moderate injury. The symbol
may also be used for property damage warnings.
IMPORTANT (NOTE)
This symbol indicates operator tips, particularly
useful information or important information about
the product or its further uses. The signal word
‘IMPORTANT (NOTE)’ does not indicate a dangerous
or harmful situation.
Safety precautions
Be sure to read, understand and follow the instructions
contained within this manual before and during use of the
equipment. Failure to do so could result in bodily harm or
damage to the equipment.
WARNING – BODILY INJURY
Installation, operation, maintenance and servicing
must be performed:
• by suitably trained personnel only
• in accordance with the information provided in
this manual
• in accordance with relevant national and local
regulations
Intended use
This sensor is intended for the following uses:
• To measure the volumetric flow rate, flow velocity, volume
flow (forward, reverse and net) and pressure (option) of a
conductive fluid.
The sensor has been designed for use exclusively within the
technical limit values indicated on the identification plate and
in the data sheets.
In terms of the measuring medium, observe following points:
• Wetted parts such as measuring electrodes, liner,
grounding electrodes, grounding rings, protection flanges
must not be damaged by the chemical and physical
characteristic of the measuring medium.
• The information on the name plate must be observed.
Improper use
The following are considered to be instances of improper use of
the sensor:
• For operating as a flexible adapter in piping – for example,
compensating pipe offsets, pipe vibrations, pipe
expansions.
• For use as a climbing aid – for example, for mounting
purposes.
• For use as a support – for example, external loads or as a
support for piping.
• Material application – for example, by painting over the
nameplate or welding / soldering on parts.
• Material removal – for example, by spot drilling the
housing.

AQUAMASTER4 | ELECTROMAGNETIC FLOWMETER FLANGED SENSOR | OI/FEW400/FRV-EN REV. A
5
Potential safety hazards
FEW4 AquaMaster4 sensor – electrical
WARNING – BODILY INJURY
To ensure safe use when operating this equipment,
the following points must be observed:
• Up to 240 V AC may be present. Be sure to isolate
the supply before removing the terminal cover.
• Normal safety precautions must be taken to avoid
the possibility of an accident occurring when
operating in conditions of high pressure and / or
temperature.
Safety advice concerning the use of the equipment
described in this manual or any relevant Material
Safety Data Sheets (where applicable) can be
obtained from the Company, together with servicing
and spares information.
Safety standards
This product has been designed to satisfy the requirements of
IEC61010-1:2010 3rd edition ‘Safety Requirements for Electrical
Equipment for Measurement, Control and Laboratory Use’ and
complies with US NEC 500, NIST and OSHA.
This equipment complies with the requirements of CEI/IEC
61010-1:2010 ‘Safety Requirements for Electrical Equipment for
Measurement, Control and Laboratory Use’ and complies with
US NEC 500 and Occupational Safety & Health Administration.
If the equipment is used in a manner NOT specified by the
Company, the protection provided by the equipment may be
impaired.
Waste Electrical and Electronic Equipment
(WEEE)
WEEE EU Directive 2012/19/EU covers disposal and recycling of
electronic equipment at the end of life for reasons of
environmental protection.
For industrial installations, portable equipment is
included. This means that when the AquaMaster4
transmitter is used with a remote sensor, it is
included in directive’s scope and has the WEEE
symbol (left) on its data label. Therefore, at the end of
life, contact the supplier for specialist waste
recycling. It must not be disposed of as municipal
waste.
Permanent industrial installations are not designated within
this directive for recycling. At the point of supply the intended
use is not always known, so the WEEE symbol is included on all
remote forms of the AquaMaster4 transmitter.
Product recycling and disposal (Europe only)
Electrical equipment marked with this symbol may
not be disposed of in European public disposal
systems after 12 August 2005. To conform to
European local and national regulations (EU Directive
2012/19/EU), European electrical equipment users
can now return old or end-of-life equipment to the
manufacturer for disposal at no charge to the user.
ABB is committed to ensuring that the risk of any
environmental damage or pollution caused by any of
its products is minimized as far as possible.
IMPORTANT (NOTE)
For return for recycling, please contact the equipment
manufacturer or supplier for instructions on how to
return end-of-life equipment for proper disposal.

6
AQUAMASTER4 | ELECTROMAGNETIC FLOWMETER FLANGED SENSOR | OI/FEW400/FRV-EN REV. A
… 1 Health & Safety
Information on ROHS Directive 2011/65/EU
(RoHS II)
ABB, Industrial Automation, Measurement & Analytics, UK, fully
supports the objectives of the ROHS II directive. All in-scope
products placed on the market by IAMA UK on and following the
22nd of July 2017 and without any specific exemption, will be
compliant to the ROHS II directive, 2011/65/EU.
Product symbols
Symbols that may appear on this product are shown below:
Risk of electric shock.
This symbol, when noted on a product, indicates a
potential hazard which could cause serious personal
injury and / or death. The user should reference this
instruction manual for operation and / or safety
information.
Protective earth (ground) terminal.
Functional earth (ground) terminal.
Direct current supply only.
Alternating current supply only.
This symbol, when noted on a product enclosure or
barrier, indicates that a risk of electrical shock and /
or electrocution exists and indicates that only
individuals qualified to work with hazardous voltages
should open the enclosure or remove the barrier.
Recycle separately from general waste under the
WEEE directive.

AQUAMASTER4 | ELECTROMAGNETIC FLOWMETER FLANGED SENSOR | OI/FEW400/FRV-EN REV. A
7
2 Sensors overview
R-series | reduced bore
Figure 1 R-series DN40 to DN300
Figure 2 R-series DN350 to DN600
V-series | octagonal bore
Figure 3 V-series DN40 to DN200

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AQUAMASTER4 | ELECTROMAGNETIC FLOWMETER FLANGED SENSOR | OI/FEW400/FRV-EN REV. A
… 2 Sensors overview
F-series | full bore
Figure 4 F-series DN250 to DN400
Figure 5 F-series DN450 to DN600
Figure 6 F-series DN700 to DN2400

AQUAMASTER4 | ELECTROMAGNETIC FLOWMETER FLANGED SENSOR | OI/FEW400/FRV-EN REV. A
9
3 Product identification
Nameplate
Integral sensor
40m 3/hr Q3/Q1(R): 500Q3:
A Model type / number
B Sensor-specific tag
C ABB-defined product serial number
D Power supply, m in. / max. voltage rating
E Logger (shown if available)
F Enclosure ingress protection rating
G Sensor size / manifold absolute pressure (psig) / temperature
H OIML R49 accuracy class
I Highest flow rate within rated operating conditions
J Sensor disposal categories
K Applicable certification
Figure 7 Name plate – integral sensor (example)
Remote sensor
40m 3/hr Q3/Q1(R): 250
40m 3/hr Q3/Q1(R): 250
A Model type / number
B Sensor-specific tag
C ABB-defined product serial number
D Enclosure ingress protection rating
E Sensor size
F OIML R49 accuracy class
G Highest flow rate within rated operating conditions
H Disposal categories
I Applicable certification
Figure 8 Name plate – remote sensor (example)

10
AQUAMASTER4 | ELECTROMAGNETIC FLOWMETER FLANGED SENSOR | OI/FEW400/FRV-EN REV. A
4 Transport and storage
Inspection
Check the sensors immediately after unpacking for possible
damage that may have occurred from improper transport.
Details of any damage that has occurred in transit must be
recorded on the transport documents. All claims for damages
must be submitted to the shipper without delay and before
installation.
Transport
WARNING – BODILY INJURY
Life-threatening danger due to suspended loads. In
the case of suspended loads, a danger of the load
falling exists.
Remaining under suspended loads is prohibited.
WARNING – RISK OF INJURY DUE TO SENSOR
SLIPPING.
The sensor’s center of gravity may be higher than the
harness suspension points.
• Make sure that the sensor does not slip or turn
during transport.
• Support the sensor laterally during transport.
Flanged sensors ≤ DN 450
• Carrying straps must be used to transport flanged designs
smaller than DN 450.
• Wrap the straps around both process connections when
lifting the sensor.
• Do not use chains as they may damage the housing.
Figure 9 Transport instructions ≤DN 450
Flanged sensors ≥ DN 450
• Flanged sensors must not be lifted by the center of the
housing when using a forklift for transport.
• Flanged sensors must not be lifted by the terminal box or by
the center of the housing.
• Only the transport lugs fitted to the sensor can be used to lift
the sensor and insert it into the piping.
Figure 10 Transport instructions ≥DN 450
Storing the sensor
Note the following when storing sensors:
• Store the sensor in its original packaging in a dry and dust-
free location.
• Observe the permitted ambient conditions for transport
and storage.
• Do not store the sensor in direct sunlight.
Storage temperature
–20 to 70 °C (–4 to 158 °F)
The ambient conditions for the transport and storage of the
sensor must correspond to the ambient conditions for
operation of the sensor.
Adhere to the AquaMaster4 data sheet (DS/FET400-EN)!

AQUAMASTER4 | ELECTROMAGNETIC FLOWMETER FLANGED SENSOR | OI/FEW400/FRV-EN REV. A
11
5 Installation
General information
The following points must be observed during installation:
• The flow direction must correspond to the marking, if
present. The flow direction must correspond to the
identification plate. The sensor measures the flowrate in
both directions. Forward flow is the factory setting.
• Secure the flange bolts and nuts against pipe vibration.
• The sensors must be installed without mechanical tension
(torsion, bending).
• Install flanged sensors with plane parallel counter flanges
and use appropriate gaskets only.
• Only gaskets made from a material that is compatible with
the measuring medium and measuring medium
temperature must be used.
• Gaskets must not extend into the flow area, since possible
turbulence could influence the accuracy of the sensor.
• The piping may not exert any inadmissible forces or
torques on the sensor.
• Ensure temperature limits are not exceeded operating
the sensor.
• Vacuum shocks in the piping should be avoided to prevent
damage to the liners. Vacuum shocks can destroy the
sensor.
• Do not remove the sealing plugs in the cable glands until
you are ready to install the electrical cable.
• The transmitter with a remote mount design must be
installed at a largely vibration-free location.
• Do not expose the transmitter and sensor to direct
sunlight. Provide appropriate sun protection as necessary.
• When installing the transmitter in a control cabinet, make
sure adequate cooling is provided.
• When installing a remote mounted transmitter ensure the
sensor and the transmitter are compatible (been assigned
correctly). Compatible sensors have the same end numbers
on the name plate, e.g. flowmeter sensor X001 belongs to
transmitter Y001 or flowmeter sensor X002 belongs to
transmitter Y002.
Installation requirements
Lay lengths
Before installing sensors, ensure lay lengths are correct for
installation requirements.
CAUTION
The installation conditions shown must be observed
to achieve the best operational results.
Unpacking the sensor
Care must be taken when lifting the sensor to use the lifting
hooks provided or sling under the body of the meter. Never lift
the sensor using the terminal box as this causes damage and
invalidates the warranty.
Sling angle <90°
Figure 11 Unpacking
Fluid level
The sensor tube must always be completely full.
Figure 12 Fluid level in pipe

12
AQUAMASTER4 | ELECTROMAGNETIC FLOWMETER FLANGED SENSOR | OI/FEW400/FRV-EN REV. A
…5 Installation
…Installation requirements
Pipeline support
The sensor must be installed without mechanical tension
(torsion, bending). If necessary, support the pipeline.
Supports
Figure 13 Pipeline support
Extremes of temperature
Do not install the sensor in a position that will expose it
to extremes of temperature (direct sunlight, frost, snow).
Provide appropriate weather protection where necessary.
Figure 14 Extremes of temperature / adverse environments
Seal materials / fluid temperatures
The flange seal material must be compatible with the fluid
and fluid temperatures.
–20 °C
(–4 °F)
m in.
70 °C
(158 °F)
max.
Figure 15 Within temperature limits
Pipeline forces / torque
The pipeline must not exert any forces and torques on the
sensor (for example, vibration).
Figure 16 Vibration
Spillage onto the sensor
Do not install the sensor in an area where a spillage of any
substance could damage the sensor.
Figure 17 Spillage

AQUAMASTER4 | ELECTROMAGNETIC FLOWMETER FLANGED SENSOR | OI/FEW400/FRV-EN REV. A
13
Flow direction / straight pipe requirements
Ensure the flow direction in the pipeline corresponds to the
identification plate. The sensor measures the flowrate in both
directions. Forward flow is the factory setting.
V-style sensor: in most installations, a straight upstream
section 5 x pipe diameters in length and a straight downstream
section 0 x pipe diameters in length are sufficient.
5 x pipe
diameters min.
>0 x pipe
diameters min.
Flow direction
Figure 18 V-style sensor –
flow direction / straight pipe requirements
R-style sensor: straight upstream and downstream sections
0 x 0 pipe diameters in length are recommended.
0 x pipe diameter 0 x pipe diameter
Flow direction
Figure 19 R-style sensor –
flow direction / straight pipe requirements
F-style sensor: in most installations, a straight upstream
section 5 x pipe diameters in length and a straight downstream
section 2 x pipe diameters in length are sufficient.
5 x pipe
diameters min.
>2 x pipe
diameters min.
Flow direction
Figure 20 F-style sensor –
flow direction / straight pipe requirements
Electrode axis
The electrode axis must be horizontal wherever possible or
no more than 45° from horizontal.
45° max.
Electrode axis
Figure 21 Flow conditions / orientation (electrode axis)

14
AQUAMASTER4 | ELECTROMAGNETIC FLOWMETER FLANGED SENSOR | OI/FEW400/FRV-EN REV. A
…5 Installation
Localized heating / welding
The sensor must not be submitted to localized heating during
installation; take care to remember this is a measuring
instrument.
Figure 22 Localized heat
Environmental rating
Ensure the level of IP rating is correct for the required meter
installation application. IP68 (NEMA 6P) rated meters can be
submerged continuously.
10 m
(30 ft)
IP68 (NEMA 6P)
Figure 23 Within environmental rating
Gasket fitting
Use correctly sized gaskets. Do NOT fit gaskets that extend
into the flow area – the turbulence caused adversely affects
sensor accuracy.
Figure 24
Fit gaskets
Gaskets
same size
as pipe
Fit gaskets same size as pipe
Cable routing
IMPORTANT NOTE
Do not attempt to join signal cable to increase cable
length.
The cable to the sensor must be installed neatly or within a
conduit. Both loose or conduit installations must have a u-bend
below terminal box height to enable any water to run off thus
avoiding any capillary action into the sensor.
Figure 25 Cable routing to enable water run off
Observe the following points when routing signal cables:
• Keep the remote form sensor cable as short as possible
to avoid unnecessary electrical and magnetic pickup.
Lengths* up to 150 m (492 ft) are permitted, but are more
susceptible to unwanted pickup.
• Avoid routing the cable in the vicinity of electrical
equipment or switching elements that can create stray
fields, switching pulses and induction
• Avoid running sensor cables adjacent to those from other
electromagnetic flowmeters, especially in the same cable
ducts, as unwanted magnetic coupling can induce
unwanted signals and cause incorrect operation of the
sensor. Ideally, adjacent cables should be >200 mm
(8 in.) apart.
• Do not damage the sheathing of the cable during
installation.
• Ensure that a drip loop (water trap) is used when installing
the connecting cables for the sensor.
*SensusTM cable is available in 5 and 20 m (15 and 65 ft)
lengths. Renewable energy cable is available as a 10 m
(30 ft) length.

AQUAMASTER4 | ELECTROMAGNETIC FLOWMETER FLANGED SENSOR | OI/FEW400/FRV-EN REV. A
15
Burying a sensor
When burying a sensor, ensure it can be found easily if required
(for example, mark the installation position with a post).
Installing a protection plate above the meter is also
recommended.
CAUTION
For further advice when burying sensors, contact the
ABB Service Organization.
Backfill Protection
plate
recommended
Figure 26 Underground installations
Sensor separation
If F-, V-, R-style sensors are installed in adjacent pipelines,
ensure they are at least 0.7 m (2.3 ft) apart to prevent the
electromagnetic field from one meter affecting the other.
0.7 m (2.3 ft) M in.
Figure 27 Sensor separation

16
AQUAMASTER4 | ELECTROMAGNETIC FLOWMETER FLANGED SENSOR | OI/FEW400/FRV-EN REV. A
…5 Installation
Dimensions
R-style sensor – DN 40 to DN 300 (1 to 12 in.)
184
(7. 2)
89
(3.5)
G
'N' x Ø 'Y'
Equispaced on
'P' PCD
F
Lifting lug Ø 'A'
2 Positions
84
(3.3)
Ø 103
(4.1)
Direction of flow
145
(5.7)
93
(3.7)
Ø D
L
Figure 28 R-style sensor – DN 40 to DN 300 (1½ to 12 in.)
Sensor
size
Flange Dimensions in mm (in.) Approx. weight
kg (lbs)
Standard Class Flange
OD
No.
holes
Bolt hole
dia.
Bolt hole
PCD
Sensor
length
Tx.
height
T. box
height
Lifting
lug
D N Y P L F G A Integral Remote

 
  

 

 
N/A
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   
 Table E  
   
    
   


  

 
 

N/A
 
  
 Table E   
  
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   


 

 

 
N/A
  
 

 
 Table E   
   
 
    
   


    

 
N/A
 
 

 
 Table E   
   
 
    
   
Table 1 R-style sensor – DN 40 to DN 80 (1½ to 3 in.)

AQUAMASTER4 | ELECTROMAGNETIC FLOWMETER FLANGED SENSOR | OI/FEW400/FRV-EN REV. A
17
Sensor
size
Flange Dimensions in mm (in.)
Approx. weight
kg (lbs)
Standard Class Flange
OD
No.
holes
Bolt hole
dia.
Bolt hole
PCD
Sensor
length
Tx.
height
T. box
height
Lifting
lug
D N Y P L F G A Integral Remote


 
 
 

 
N/A
 
  
   
 Table E   
   
  

  


   
   


 


 

 
N/A
   
   
 Table E   
   
    
   


 


 
 


 
   
   
  
 Table E   
  

   
   
    



   


 
 
 
   
  

 
 Table E  
  
  

   
   
    



 

 
     
   
   
 Table E   
  

    
   
    
     



    
     

   
    
 Table E    
  

    
   
    
     
Table 2 R-style sensor – DN 100 to DN 300 (4 to 12 in.)

18
AQUAMASTER4 | ELECTROMAGNETIC FLOWMETER FLANGED SENSOR | OI/FEW400/FRV-EN REV. A
…5 Installation
…Dimensions
R-style sensor – DN 350 to DN 600 (14 to 24 in.)
184
(7. 2)
89
(3.5)
G
'N' x Ø 'Y'
Equispaced
on 'P' PCD
F
Lifting lug Ø 'A'
2 Positions
C
84
(3.3)
Ø 103
(4.1)
Direction of flow
145
(5.7)
93 (3.7)
Ø D
L
Figure 29 R-style sensor – DN 350 to DN 600 (14 to 24 in.)

AQUAMASTER4 | ELECTROMAGNETIC FLOWMETER FLANGED SENSOR | OI/FEW400/FRV-EN REV. A
19
Sensor
size
Flange Dimensions in mm (in.)
Approx. weight
kg (lbs)Standard Class Flange
OD
No.
Holes
Bolt hole
dia
Bolt hole
PCD
Sensor
length
Tx.
height
T. box
height
Lifting
lug
Cover
flat
D N Y P L F G A C Integral Remote



 

 
   
   
   
   
ASME
  

 
 Table E   
 

 


   
   



 

 
   
   
   
   
ASME
    
 Table E    
 

    
   
    



 

 
   
   
   
   
ASME
     
 Table E    
  

    
    
   



 

 
   
   
   
   
ASME
    
 Table E    
 

    
    
   



 

 
   
   
   
  
ASME
    
 Table E    
  

    
   
    
Table 3 R-style sensor – DN 350 to DN 600 (14 to 24 in.)

20
AQUAMASTER4 | ELECTROMAGNETIC FLOWMETER FLANGED SENSOR | OI/FEW400/FRV-EN REV. A
…5 Installation
…Dimensions
V-style sensor – DN 40 to DN 200 (1 to 8 in.)
89
(3.5)
G
'N' x Ø. 'Y'
Equispaced
on 'P' PCD
X
184
(7. 2)
F
84
(3.3)
Ø 103
(4.1)
Direction of flow
Lifting lug Ø 'A'
2 Positions
145
(5.7)
L
Ø D
93
(3.7)
Figure 30 V-style sensor – DN 40 to DN 200 (1½ to 8 in.)