ABB AquaMaster Explorer User manual

Electronic Commercial Water Meter
Powered by External Battery Pack
AquaMasterTM Explorer
Installation Manual
IM/AM/E_5

ABB
EN ISO 9001:2000
Cert. No. Q5907
The Company
We are an established world force in the design and manufacture of
instrumentation for industrial process control, flow measurement, gas and liquid
analysis and environmental applications.
As a part of ABB, a world leader in process automation technology, we offer
customers application expertise, service and support worldwide.
We are committed to teamwork, high quality manufacturing, advanced
technology and unrivalled service and support.
The quality, accuracy and performance of the Company’s products result from
over 100 years experience, combined with a continuous program of innovative
design and development to incorporate the latest technology.
The UKAS Calibration Laboratory No. 0255 is just one of the ten flow calibration
plantsoperatedbytheCompany,andisindicativeofourdedicationtoqualityand
accuracy.
EN 29001 (ISO 9001)
Lenno, Italy – Cert. No. 9/90A
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S
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Electrical Safety
ThisequipmentcomplieswiththerequirementsofCEI/IEC61010-1:2001-2"Safetyrequirementsforelectricalequipmentfor
measurement, control, and laboratory use". If the equipment is used in a manner NOT specified by the Company, the
protection provided by the equipment may be impaired.
Symbols
One or more of the following symbols may appear on the equipment labelling:
Information in this manual is intended only to assist our customers in the efficient operation of our equipment. Use of this
manual for any other purpose is specifically prohibited and its contents are not to be reproduced in full or part without prior
approval of the Technical Communications Department.
Warning – Refer to the manual for instructions
Caution – Risk of electric shock
Protective earth (ground) terminal
Earth (ground) terminal
Direct current supply only
Alternating current supply only
Both direct and alternating current supply
The equipment is protected
through double insulation
Stonehouse, UK
Health and Safety
To ensure that our products are safe and without risk to health, the following points must be noted:
1. The relevant sections of these instructions must be read carefully before proceeding.
2. Warning labels on containers and packages must be observed.
3. Installation, operation, maintenance and servicing must only be carried out by suitably trained personnel and in
accordance with the information given.
4. Normalsafetyprecautionsmustbetakentoavoidthepossibilityofanaccidentoccurringwhenoperatinginconditions
of high pressure and/or temperature.
5. Chemicalsmustbestoredawayfromheat,protectedfromtemperatureextremesandpowderskeptdry.Normalsafe
handling procedures must be used.
6. When disposing of chemicals ensure that no two chemicals are mixed.
Safety advice concerning the use of the equipment described in this manual or any relevant hazard data sheets (where
applicable) may be obtained from the Company address on the back cover, together with servicing and spares
information.
0255

1
CONTENTS
AquaMasterTM is a range of high performance
electromagnetic flowmeters for the measurement
of electrically conductive fluids and are normally
supplied as factory configured, calibrated
systems.
Warning.
•Installation and maintenance must
be carried out only by suitably trained
personnel.
•Read all relevant sections of this
manual before selecting a location.
•The safety requirements of this
equipment, any associated
equipment and the local environment
must be taken into consideration
during installation.
•Install and use this equipment in
accordance with relevant national
and local standards.
•Specific safety precautions apply to
the use of the GSM engine which
forms part of the GSM-equipped
version of this product. If the unit
purchased has GSM-capability, read
Appendix A on page 24 before
selecting a location.
1INTRODUCTION
1INTRODUCTION ......................................... 1
2MECHANICAL INSTALLATION .................. 2
2.1 Unpacking .......................................... 2
2.2 Installation Conditions ........................ 2
2.3 Transmitter Dimensions ...................... 4
2.4 GSM-equipped Transmitters .............. 5
2.4.1 GSM Antenna Installation ....... 5
2.4.2 Connecting a Remote
Antenna ................................. 7
2.4.3 Installing a SIM Card .............. 8
3ELECTRICAL INSTALLATION .................... 9
3.1 Bonding/Grounding ............................ 9
3.2 Connections ..................................... 14
3.2.1 Sensor Terminal Box
Connections (Remote Versions
only) ..................................... 14
3.2.2 Environmental Protection ...... 14
3.2.3 Transmitter Connections ............... 17
3.3.1 Frequency Outputs ............... 17
3.3.2 Alarm Interface ..................... 17
3.3.3 Connector Input/Output
Connections ........................ 18
3.3.4 Local Computer Connection 19
3.3.5 Pressure Transducer ............. 20
4START-UP AND OPERATION .................. 21
4.1 Start-up ............................................ 21
4.2 Display Activation ............................. 22
4.3 Battery Replacement ........................ 22
4.4 Accessories/Spares Kits ................... 23
SPECIFICATION ............................................. 24
APPENDIX A – GSM-EQUIPPED UNITS –
SAFETY PRECAUTIONS ............................... 26
Safety Precautions .................................... 26
NOTES ............................................................ 27

2
Allow room to
read display
>2 x pipe dia.
minimum
>5 x pipe dia.
minimum
Flow Direction
60C (140F)
Maximum
–20C (–4F)
Minimum
AquaMaster
AquaMaster
AquaMaster AquaMaster
2MECHANICAL INSTALLATION
2.1 Unpacking
2.2 Installation Conditions – Figs. 2.1 to 2.17
Caution.Do NOT exceed the maximum
working pressure marked on the
equipment.
Fig. 2.1 Unpacking
Fig. 2.2 Spillage
Fig. 2.3 Vibration
Fig. 2.4 Localized Heat
Fig. 2.5 Siting
Fig. 2.6 Straight Pipe Requirements
Fig. 2.7 Fluid Level
Fig. 2.8 Within Temperature Limits
Fig. 2.9 Shade

3
Supports
< 2m
(78in)
IP68 (NEMA 6P/
ENCLOSURE 6P)
Submerged
9 Months
Accrued Time
Backfill
(Recommended)
Adequate
Protection
Plate
80C (176F)
Maximum
–10C (14F)
Minimum
Fit gaskets
Gasket same
size as pipe
0.7m (2.3 ft)
minimum
For access to batteries, display
and communication connector.
2MECHANICAL INSTALLATION…
Fig. 2.10 Above Ground
Fig. 2.11 Temperature Difference
Fig. 2.12 Within Environmental Rating
Fig. 2.13 Underground
Fig. 2.14 Cable Routing
Fig. 2.15 Gasket Fitting
Fig. 2.16 Separation of Sensors
Fig. 2.17 Access to Transmitter

4
AquaMaster
168
(6.6)
50
(2.0)
115
(4.5)
177
(7.0)
Ø6.5
(0.3)
Ø13
(0.5)
136
(5.4)
21
(0.8)
…2 MECHANICAL INSTALLATION
2.3 Transmitter Dimensions – Fig. 2.18 and 2.19
Fig. 2.18 Transmitter Dimensions
Fig. 2.19 Battery Pack Dimensions
135
(5.3)
135
(5.3)
8
(0.3)
70
(2.75)
Dimensions in mm (in.)
Dimensions in mm (in.)

5
50mm
50mm
Remote
Antenna
Integral
Antenna
2MECHANICAL INSTALLATION…
2.4 GSM-equipped Transmitters
2.4.1 GSM Antenna Installation – Figs. 2.20 and 2.21
Before deciding on an antenna mounting location, check that the local signal strength for the chosen
mobile phone network is satisfactory. Use the GSM-equipped transmitter's integral signal strength test
facility to establish signal strength. Refer to 'Commissioning test for signal strength' in the Quick
Reference Guide for the AquaMaster S with GSM (IM/AMG–QRG).
If a GSM-equipped transmitter is not available, a standard mobile phone on the same network, positioned
as close as possible to the intended location, will give a good indication of local signal strength. For GSM
and logger download services, a minimum of two visible signal strength indicator 'bars' are
recommended. For SMS text, a minimum of one visible signal strength indicator 'bar' is recommended.
The following must also be observed when deciding on the antenna mounting location:
•For best results, mount the antenna as high above local ground level as possible.
•If the antenna must be mounted below ground, achieve optimum results by ensuring:
–there is a strong mobile phone network signal at ground level
–the antenna is mounted 50mm below the chamber cover, which must be plastic – see Fig. 2.20
•Ensure the antenna will not become submerged under water – see Fig. 2.20.
•Metallic enclosures will seriously degrade the signal. If an enclosure is used it must be non-
metallic.
•Do not mount the antenna closer than 50mm to any solid wall or surface – see Fig 2.21.
•Do not mount the antenna beneath a solid surface (e.g. metal cover, floor/ceiling, etc).
Fig. 2.20 GSM Antenna Installation

6
50mm
(2 in.)
Fig. 2.21 GSM Antenna Installation
…2 MECHANICAL INSTALLATION
…2.4.1 GSM-equipped Transmitters

7
AquaMaster 1Remove the cover from the socket on
top of the transmitter.
2Gently push the antenna plug into the
socket, then twist the screw ring clockwise
until locked.
2
1
2MECHANICAL INSTALLATION…
2.4.2 Connecting a Remote Antenna – Fig. 2.22
Fig. 2.22 Connecting a Remote Antenna

8
…2 MECHANICAL INSTALLATION
1Remove the transmitter from its mounting point.
Use water to wash off any loose dirt from the case.
On the back of the transmitter, unscrew and remove
the cover to the SIM card holder.
2
3
6
3Carefully lift the right-hand edge
of the holder outwards.
Slide the SIM card into the carrier,
contact side down and bevelled
edge to the top-right.
Close the holder until it clicks into
place and refit the cover.
5
4
Fig. 2.23 Installing a SIM Card
…2.4 GSM-equipped Transmitters
2.4.3 Installing a SIM Card – Fig. 2.23

9
3.1 Bonding/Grounding – Figs. 3.1 to 3.9
Caution.For safety reasons and optimum performance, the flowmeter, pipelines and medium
must be correctly bonded and grounded according to regulations.
Notes.
•The flow sensor must not be connected to a ground spike.
•For bonding connections use 4mm2(<10AWG) cable.
•Sensors 80mm do not require grounding rings.
•Connect the transmitter ground connection to the flowmeter body ground – see Figs 3.6 and
3.7.
Fig. 3.1 All Metal Pipe, Including Lined Metal Pipe.
Fluid Contact Rings
See Figs. 3.6 and 3.7
Key for Figs. 3.1 to 3.9
Metal Pipes
Plastic Pipes
Fluid Contact Rings
See Figs. 3.6 and 3.7
Insulation
Fig. 3.2 Metal Pipe With Flange Adaptor
3ELECTRICAL INSTALLATION

10
Fluid Contact Rings
See Figs. 3.6 and 3.7
Fluid Contact Rings
See Figs. 3.6 and 3.7
Fluid Contact Rings
See Figs. 3.6 and 3.7
Fig. 3.3 Flanged Metal Pipe to Plastic Pipe
Fig. 3.5 All Plastic Pipe
…3 ELECTRICAL INSTALLATION
Fig. 3.4 Metal Pipe With Plastic Make-Up Insert

11
3ELECTRICAL INSTALLATION…
Fig. 3.6 Battery Powered Transmitter Mounted in a Chamber
Fig. 3.7 Mains or Battery Powered Transmitter in Roadside Cabinet with Local Ground

12
Fluid Contact Rings
Insulating Sleeve
and Washer
(not supplied)
Insulated connecting wire
(not supplied). Must be
adequately rated to carry
cathodic currents.
Gasket Gasket
Bonding Cable
(supplied)
Fluid Contact
Ring
Bonding Cables
(supplied)
…3 ELECTRICAL INSTALLATION
Caution. Do NOT
ground Cathodically
Protected Systems.
Fig. 3.8 Pipelines With Cathodic Protection, DN100mm

13
Insulating Sleeve
and Washer
(not supplied)
Insulated connecting wire
(not supplied). Must be
adequately rated to carry
cathodic currents.
Gasket
Bonding Cable
(supplied)
3ELECTRICAL INSTALLATION…
Fig. 3.9 Pipelines With Cathodic Protection, DN 40mm to 80mm
Caution. Do NOT
ground Cathodically
Protected Systems.

14
3.2 Connections
3.2.1 Sensor Terminal Box Connections (Remote Versions only) – Fig. 3.10
Caution. (Remote versions)
•Remove foil screens completely, and plastic/foil screens and any fillers
•Twist the three screen wires together and sleeve them.
•Keep cable pairs twisted.
•Make connections only as shown.
•Maintain Environmental Protection at all times.
•Conduit connections must provide cable entry sealing.
…3 ELECTRICAL INSTALLATION
3.2.2 Environmental Protection – Fig 3.11
Warning.
•Potting materials are toxic – use suitable
safety precautions.
•Read the manufacturers instructions carefully
before preparing the potting material.
•The remote sensor terminal box connections
must be potted immediately on completion to
prevent the ingress of moisture.
•Check all connections before potting – see
ELECTRICAL INSTALLATION.
•Do not overfill or allow the potting material to
come into contact with ‘O’ rings or grooves.
•Do not let potting material enter conduit, if
used.
Fig. 3.11 Potting the Terminal Box
Fig. 3.10 Sensor Terminal Box Connections (Remote Version)
CABLE
ABB
Violet
Blue
Green (Sleeved Ground)
Yellow
Orange
Red
Brown
Maximum Cable Lengths
STT 4000 Series: 80 m
STT 4005 Series: 250 m
Belden 8777: 80 m
Belden 8777
White
Black
Sleeved Ground
Red
Black
Green
Black
Caution. With Belden Cable 8777, ensure that the black wires are
not interchanged and remain with the associated pair.

15
3ELECTRICAL INSTALLATION…
Fig. 3.12 Transmitter Connections
External
Battery
Pack
Outputs
(Pulses,
Alarm,
Scanreader)
Pressure
Transducer
(Optional) Sensor Local
Comms.
1
2
Remove the screwed cap on the sensor connector.
Gently push the sensor plug into the socket and rotate it until it engages;
then tighten the locking ring.
Note: If the sensor cable is fitted with the metal MIL-spec connector, then
connection is via the MIL-spec sensor cable adapter (part number
WEBC2001, available separately).
Note: If the sensor cable is terminated with flying leads, connection is via
a sensor cable adapter box (part number WABC2024/B, available separately).
1
2
Fig. 3.13 Sensor Connection
3.2.3 Transmitter Connections – Fig 3.12 to 3.14

16
…3 ELECTRICAL INSTALLATION
Fig. 3.14 Use of Tamper-Detection Seals
1
2 3
4
1
2
Slide the optional locking-ring (from pack WEBC 2004) over the
cable to be sealed.
Connect the cable to the appropriate transmitter connector.
Slide the locking-ring over the connector.
Pass the wire of the seal through both the hole in the locking-ring
and the matching hole in the front of the transmitter. Close the seal.
3
4

17
3.3 Input/Output Connections
Caution.
•Refer to SPECIFICATION for Input/Output ratings.
•Inductive loads must be suppressed or clamped to limit voltage swings
•Operation of outputs is programmable – see Quick Reference Programming Guide for
details.
•External isolators are not normally required as the pulse and alarm circuit is electrically
separated from all other AquaMaster connections.
•Capacitive loads must be inrush current limited.
•Fully-floating pulse outputs may be subject to static damage, e.g. connecting to a floating
datalogger, unless 'COM' is operated within its galvanic isolation range (35V) from earth.
3.3.1 Frequency Outputs – Fig. 3.15
3ELECTRICAL INSTALLATION…
Fig. 3.15 Frequency Output Connections
Fig. 3.16 Alarm Output Connections
Note. Outputs 1 & 2 are not polarity sensitive. The common connection for these
outputs is designated ‘COM’.
Note. Output 3 is not polarity sensitive. The common connection for these outputs
is designated ‘COM’. Alarm functions are available only with product software
versions: 1.1 (Release 1) 2.1 (release 2). See Programming Guide to determine
software version.
Tel emetry, Electronic
Counters etc.
Counter/Totalizers
Forward Flow
and/or Reverse Flow
123456
123456
I/P0V*
COM
O/P1
O/P2
PLC or Datalogger
COM
O/P1
O/P2
Common
Input 1
Input 2
COM
O/P3
Common
Alarm Input
3.3.2 Alarm Interface – Fig. 3.16

18
…3 ELECTRICAL INSTALLATION
3.3.3 Connector Input/Output Connections – Fig. 3.17
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2ATADataDredaernacSeulB
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53P/OtuptuOmralAnworB
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1
2
3
4
5
6
7
8
Pin View
Fig. 3.17 Connector Input/Output Connections