ABB COPA-XT DT43F Training manual

COPA-XT
Instruction Bulletin
Electromagnetic Flowmeter
in 2-Wire Technology with
Pulsed DC Magnetic Fields
Models DT43F Flange Design
DT43W Wafer Design
Valid for Software Versions from A.0x
D184B094U02 Rev. 00 / 02.2001

You have purchased a high quality, modern
Electromagnetic Flomweter in a Compact Design
from Abb Automation Products. We thank you for your purchase
and the confidence you have shown in us.
This Instruction Bulletin contains the instructions relating to the
assembly and installation of the instrument and the specifications
for this instrument design. Abb Automation Products reserves the
right to make hardware and software refinements which
enhance the operation of the instrument without prior notice.
Should any questions which may arise that are not specifically answered by
these instructions please contact Abb Automation Products at our
main plant in Göttingen, Germany Tel. [phone]
or one of our Technical Sales Bureaus.
This converter and the flowmetering system comply with the
interference compatibility requirements listed in the
NAMUR-Recommendations NE21 5/93 and the
EMC Guideline 89/336/EWG (EN 50081-1, EN 50081-2)
(EN 50082-1, EN 50082-2)
Copyright durch ABB Automation Products. Alle Rechte vorbehalten

Introductory Safety Notes for the EMF System
Regulated Usage
The Electromagnetic Flowmeter [EMF] system, which consists of a flowmeter primary and a flowmeter
converter, is designed to the latest state of the art and is safe to operate. The EMF is to be installed
exclusively in the specified applications.
Every usage which exceeds the specified applications is considered to be non-specified. Any damages
resulting therefrom are not the responsibility of the manufacturer.
The user assumes all risk for such operation.
The application specifications include the installation, start up, and service requirements specified by the
manufacturer.
Installation, Start Up, and Service Personnel
Please read this Instruction Bulletin for the flowmeter primary and converter and the safety notes before
attempting installation, start up, or service of the flowmeter system.
Only qualified personnel should have access to the instrument. The personnel should be familiar with the
warnings and operating requirements contained in this Instruction Bulletin.
Check that the connections are in accordance with the interconnection diagrams. Ground the flowmeter
system.
Observe the warning notes indicated in this document by the symbol:
Hazardous Material Information
Repair
[Requirement of German Law, may be different for other countries]
In view of the Disposal Law of 27.08.86 (AbfG. 11 Special Wastes) the owner of special wastes is
responsible for its care and the employer also has, according to the Hazardous Material Law of 01.10.86
(GefStoffV, 17 General Protection Responsibility), a responsibility to protect his employees, we must make
note that:
a) All flowmeter primaries and/or flowmeterconverterswhich arereturnedto ABB Automation Products for
repair are to be free of any hazardous materials (acids, bases, solutions, etc.)
b) The flowmeter primaries must be flushed so that the hazardous materials are neutralized. There are
cavities in the primaries between the metering spool and the housing. Therefore after metering
hazardousmaterialsthecavitiesaretobeneutralized(seeHazardousMaterialLaw-GefStoffV).Fortwo
piece housings the screws used to hold the sections together should be loosened in order to
remove the hazardous material and to neutralize the coil and electrode areas
c) Forserviceandrepairswritten confirmation isrequiredthatthemeasureslistedina)andb)havebeen
carried out.
d) Any costs incurred to remove the hazardous materials during a repair will be billed to the owner of the
equipment.

Contents Page
1. Flowmeter Primary and Converter Coordination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Data Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Measurement Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3. Assembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Flowmeter Primary Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2.1 Flowmeter Primary Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2.2 Installations in Larger Size Pipelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3.1 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3.2 Supply Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3.3 Interconnection Diagram COPA-XT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3.4 Interconnection Examples for Peripherals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4. Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.1 Preliminary Flowmeter System Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.1.1 Checking the Flowmeter Primary COPA-XT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2 System Zero . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.3 Converter Exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.4 Memory Module Socket (External EEPROM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.5 Maintenance/Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.6 Rotating the Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.7 Flowmeter Primary Replacement Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5. Operation, Data Entry and Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.1 Display Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.2 Data Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.3 Data Entry Instruction in “Condensed Form”. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.4 Parameter Overview and Data Entry in "Condense Form" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6. Parameter Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.1 User Configurable Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.1.1 Units Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.1.2 Unit Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.1.3 Configurable Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.2 Submenu Function Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7. Error Messages and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8. Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
9. Overview, Parameter Settings and Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Specifications
Electromagnetic Flowmeter in a 2-Wire Design
with Pulsed DC Magnetic Field in a Compact Design
COPA-XT see Specification Sheet Part No. D184S029U02

Electromagnetic Flowmeter COPA-XT
1
1. Flowmeter Primary and Converter Coordination
This Instruction Bulletin describes the assembly and installation of the flow metering system COPA-XT with a 2-Wire Design.
1.1 Data Security
All data is stored in a FRAM when the power is turned off or a
power interruption occurs. The parameter settings, process
information and flowmeter primary specific calibration data are
stored in a FRAM as well as in an external EEPROM. There-
fore, when an electronic module and its memory module is ex-
changed all the stored data can be uploaded at any time.
!Important Start-Up Information
Data Memory Module (External EEPROM)
The converter is shipped with its appropriate EEPROM
installed in the socket on the converter display plate.
Please check that the correct coordination is maintained
between the flowmeter primary and the converter. The
converters are identified by the end numbers, A1, A2 etc. listed
on the converter Instrument Tag and in addition, the Order
Number is noted on the memory module.
Compact Design COPA-XT
The µP-converter and the flowmeter primary constitute a
single mechanical entity.
Models:
Metering System DT43F or DT43W
Wafer DesignFlanged

2
Electromagnetic Flowmeter COPA-XT
2. Principles of Operation
The ABB Automation Products electromagnetic flowmeters are
the ideal instruments for metering the flowrate of liquids, slur-
riesandsludgeswithaspecificminimumelectricalconductivity.
These flowmeters measure accurately, produce no additional
pressuredrop, contain no moving or protruding parts, are wear
and corrosion resistant. They can be installed in any existing in-
stallation without difficulty.
The ABB Automation Products “EMF” has proven itself over
many years and is the preferred flowmeter in the chemical in-
dustry, the pharmaceutical and cosmetic industries, municipal
water and waste water treatment facilities and in the food and
paper industries.
2.1 Measurement Principle
Faraday’s Laws of Induction form the basis for the
electromagnetic flowmeter. A voltage is generated in a
conductor when it moves through a magnetic field.
This principle is applied to a conductive fluid which flows
through the metering tube perpendicular to the direction of the
magnetic field, see schematic.
UE~ B · D ·v
The voltage induced in the fluid is measured by two electrodes
located diametrically opposite to each other. This flow signal
voltage UEis proportional to the magnetic induction B, the
electrode spacing D and the average flowvelocity v. Noting that
the magnetic induction B and the electrode spacing D are
constant values indicates that a proportionality exists between
the flowsignalvoltage UEandthe averageflowvelocityv. From
theequationforcalculatingthevolumeflowrate*)it followsthat
UE ~ qv, that is, the flow signal voltage UEis linear and
proportional to the volumetric flow rate.
2.2 Design
An electromagnetic flowmeter system always consists of a
flowmeter primary and a converter. In the Compact Design the
flowmeter primary and the converter constitute a single entity.
This feature coupled with the 2-Wire technology in which the
supply power and the outputs are carried on the same cable
results in appreciably lower installation expenses than for the
conventional instruments.
Magnet Coil
Metering Tube in
Electrode Plane
Electrode
Flow Signal
UE= Flow signal voltage
B = Magnetic induction
D = Electrode spacing
v = Average flow velocity
qv= Volume flowrate
*)
UE~
qv=
UE~ qv
BDv⋅⋅
D2π
---------- v⋅
Electromagnetic Flowmeter Schematic

Electromagnetic Flowmeter COPA-XT
3
3. Assembly and Installation
3.1 Inspection
Before installing the electromagnetic flowmeter primary check
for mechanical damage due to possible mishandling during
shipment. All claims for damage areto be made promptly to the
shipper before installing the flowmeter.
3.2 Flowmeter Primary Installation Requirements
The flowmeter primary should not be installed in the vicinity of
strong electromagnetic fields.
The electromagnetic flowmeter primary must be installed so
that the metering tubeis always filledwith fluid. Valves or other
shut off devices should be installed downstream from the EMF
so that the flowmeter primary cannot drain. A slight upward
slope of approx. 3 % is desirable to preventing gas build up in
the flowmeter (Fig. 1).
Vertical installations are ideal when the fluid flows in an upward
direction. Installations in drop lines, i.e. the fluid flows from the
top to the bottom are to be avoided because experience has
shown that it is not possible to guarantee that the pipeline will
remain full and that an equilibrium condition between the
upward flowing gas and the downward flowing liquid will not
occur (Fig. 2).
The flowmeter primary should generally be installed so that the
electrical connectors (Pg) point downward
(Figs. 2 & Fig. 4).
In horizontal installations the imaginary line connecting the
electrodes should be horizontal so that air or gas bubbles can-
not influence the flow signal voltage that is measured at the
electrodes. The electrode orientation is shown in Fig. 3.
For a free flow in- or outlet an invert should be provided to
assure that the flowmeter primary is always filled with fluid
(Fig. 4).
Fig. 1
Fig. 2
Imaginary
Electrode Axis
Fig. 3
Fig. 4

4
Electromagnetic Flowmeter COPA-XT
In a free flowoutlet (drop line) the flowmeter primary should be
not be installed in the highest point or in the discharge of the
pipeline (metering spool could drain, air bubbles, Fig. 5)
The measurement principle is independent of flow profile as
long asstanding eddies do notextend into the measurementre-
gion (e.g. after double elbows, tangential inflows or half open
valves upstream of the flowmeter primary). In such situations
measures to condition the flow profile should be employed. Ex-
perience indicates that in most cases a straight upstream sec-
tion with a length of3 x DN and a downstream section of 2x DN
are sufficient (DN = flowmeter primary size) Fig. 6.
In calibration stands the reference conditions of EN 29104 re-
quire straight lengths of 10 x DN upstream and 5 x DN down-
stream.
Wafer valves are tobe installed insuch a manner that thewafer
when open does not extend into the flowmeter. Valves or other
shut off devices should be installed downstream.
For heavily contaminated fluids a bypass line as shown in
Fig. 7 is recommended so that when mechanical cleaning is
required operation can continue uninterrupted.
.
For flowmeter primaries which are to be installed in the vicinity
of pumps or other vibration generating equipment, the
utilization of mechanical dampers is advantageous (Fig. 8).
Fig. 5
Fig. 6
F
ig. 7
F
ig. 8