ABB FEX300 User manual

Operating Instruction
OI/FEX300/FEX500-EN
Electromagnetic Flowmete
r
ProcessMaster, HygienicMaste
r
FEX300, FEX500
Valid from software version
• 01.01.00 for HART
• 00.01.00 for PROFIBUS PA or
FOUNDATION Fieldbus

Blinder Text
2 FEX300, FEX500 OI/FEX300/FEX500-EN
Electromagnetic Flowmeter
ProcessMaster, HygienicMaster
FEX300, FEX500
Operating Instruction
OI/FEX300/FEX500-EN
07.2011
Rev. D
Translation of the original instruction
Manufacturer:
ABB Automation Products GmbH
Dransfelder Straße 2
D-37079 Göttingen
Germany
Tel.: [phone]
Fax: [phone]
Customer service center
Phone: [phone]
Fax: [phone]-29031
[email protected]
ABB Inc.
125 E. County Line Road
Warminster, PA 18974
USA
Phone: [phone]
Fax: [phone]
[email protected].com
ABB Engineering (Shanghai) Ltd.
No.5, Lane 369, Chuangye Road,
Kangqiao Town, Nanhui District
Shanghai, 201319, P.R. China
Phone: [phone]
Fax: [phone]
© Copyright 2011 by ABB Automation Products GmbH
Subject to changes without notice
This document is protected by copyright. It assists the user in safe and efficient operation of the device. The contents of this
document, whether whole or in part, may not be copied or reproduced without prior approval by the copyright holder.
Contents

Contents
OI/FEX300/FEX500-EN FEX300, FEX500 3
1Safety.............................................................................................................................................................7
1.1 General information and notes for the reader ................................................................................................7
1.2 Intended use...................................................................................................................................................8
1.3 Improper use ..................................................................................................................................................8
1.4 Target groups and qualifications ....................................................................................................................8
1.5 Warranty provisions........................................................................................................................................8
1.6 Plates and symbols ........................................................................................................................................9
1.6.1 Safety-/ warning symbols, note symbols.................................................................................................9
1.6.2 Name plate............................................................................................................................................10
1.7 Transport safety information.........................................................................................................................13
1.8 Installation safety information.......................................................................................................................13
1.9 Safety instructions for electrical installation .................................................................................................13
1.10 Safety instructions for operation...................................................................................................................14
1.11 Technical limit values ...................................................................................................................................14
1.12 Allowed Fluids ..............................................................................................................................................14
1.13 Maintenance and inspection safety information...........................................................................................15
1.14 Returning devices.........................................................................................................................................15
1.15 Integrated management system...................................................................................................................16
1.16 Disposal........................................................................................................................................................16
1.16.1 Information on WEEE Directive 2002/96/EC (Waste Electrical and Electronic Equipment).................16
1.16.2 RoHS Directive 2002/95/EC .................................................................................................................16
2Design and function...................................................................................................................................17
2.1 Measuring principle ......................................................................................................................................17
2.2 Device designs .............................................................................................................................................18
2.2.1 Design ...................................................................................................................................................19
2.2.2 Model with compact design...................................................................................................................19
2.2.3 Model with remount mount design........................................................................................................19
3Transport and storage ...............................................................................................................................20
3.1 Inspection .....................................................................................................................................................20
3.2 Transport of flanged units smaller than DN 450...........................................................................................20
3.3 Transport of flanged units larger than DN 400.............................................................................................21
3.4 Storage conditions........................................................................................................................................21
4Mounting .....................................................................................................................................................22
4.1 General information on installation...............................................................................................................22
4.1.1 Supports for meter sizes larger than DN 400 .......................................................................................22
4.1.2 Mounting the measuring tube ...............................................................................................................23
4.2 Torque information .......................................................................................................................................24
4.2.1 ProcessMaster in flange design and HygienicMaster in flange or wafer-type design ..........................24
4.2.2 Variable process connections HygienicMaster .....................................................................................28
4.3 Information on EHEDG conformity...............................................................................................................29
4.4 Information on 3A conformity .......................................................................................................................29
4.5 Installation Requirements.............................................................................................................................30
4.5.1 Electrode axis........................................................................................................................................30
4.5.2 In- and outlet pipe sections ...................................................................................................................30
4.5.3 Vertical connections..............................................................................................................................30
4.5.4 Horizontal connections..........................................................................................................................30
4.5.5 Free inlet or outlet .................................................................................................................................30
4.5.6 Strongly contaminated fluids.................................................................................................................30
4.5.7 Installation in the vicinity of pumps .......................................................................................................31
4.5.8 Installing the high temperature design..................................................................................................31
4.5.9 Devices with extended diagnostic functions .........................................................................................31

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4 FEX300, FEX500 OI/FEX300/FEX500-EN
4.5.10 Installation in pipelines with larger nominal diameters..........................................................................31
4.6 Rotating the display / Rotating the housing..................................................................................................32
4.6.1 Rotating the display...............................................................................................................................32
4.6.2 Rotating the housing .............................................................................................................................32
4.7 Ground..........................................................................................................................................................33
4.7.1 General information on ground connections.........................................................................................33
4.7.2 Metal pipe with fixed flanges.................................................................................................................33
4.7.3 Metal pipe with loose flanges................................................................................................................34
4.7.4 Plastic pipes, non-metallic pipes or pipes with insulating liner .............................................................35
4.7.5 Sensor type HygienicMaster .................................................................................................................36
4.7.6 Ground for devices with protective plates.............................................................................................36
4.7.7 Ground with conductive PTFE grounding plate ....................................................................................36
4.7.8 Devices with extended diagnostic functions .........................................................................................36
4.7.9 Installation and grounding in pipelines with cathodic corrosion protection (CCP)................................37
5Electrical connections ...............................................................................................................................39
5.1 Preparing and routing the signal and magnet coil cable..............................................................................39
5.1.1 Cable with part number D173D027U01................................................................................................39
5.1.2 Cable with part number D173D031U01................................................................................................40
5.2 Connecting the flowmeter sensor.................................................................................................................42
5.2.1 Connecting the signal and magnet coil cables .....................................................................................42
5.2.2 Protection class IP 68 ...........................................................................................................................43
5.3 Connecting the transmitter ...........................................................................................................................45
5.3.1 Connecting the supply power................................................................................................................45
5.3.2 Transmitter ............................................................................................................................................46
5.3.3 Devices with HART protocol .................................................................................................................47
5.3.4 Devices with PROFIBUS PA or FOUNDATION Fieldbus.....................................................................48
5.3.5 Connection examples for the peripherals .............................................................................................49
6Commissioning ..........................................................................................................................................53
6.1 Preliminary checks prior to start-up..............................................................................................................53
6.2 Configuring the current output......................................................................................................................54
6.3 Commissioning PROFIBUS PA units...........................................................................................................56
6.3.1 Example of local address setting (DIP switch 8 = On)..........................................................................57
6.3.2 Unit behavior with auxiliary power switched on ....................................................................................58
6.3.3 Voltage / current consumption ..............................................................................................................58
6.3.4 System integration ................................................................................................................................59
6.4 Commissioning FOUNDATION FIELDBUS units.........................................................................................60
6.4.1 Position of DIP switches .......................................................................................................................61
6.4.2 Bus address settings.............................................................................................................................62
6.5 Commissioning the unit................................................................................................................................63
6.5.1 Downloading the system data...............................................................................................................63
6.5.2 Parameterizing via the "Easy Set-up" menu function ...........................................................................65
6.6 Flowmeter sizes, flow range.........................................................................................................................71
7Parameterization ........................................................................................................................................72
7.1 Operation......................................................................................................................................................72
7.1.1 Menu navigation....................................................................................................................................72
7.2 Menu levels ..................................................................................................................................................73
7.2.1 Process display .....................................................................................................................................74
7.2.2 Switching to the information level (operator menu) ..............................................................................75
7.2.3 Switching to the configuration level (parameterization) ........................................................................78
7.2.4 Hardware write protection .....................................................................................................................79
7.2.5 Selecting and changing parameters .....................................................................................................80
7.3 Overview of parameters on the configuration level......................................................................................82

Contents
OI/FEX300/FEX500-EN FEX300, FEX500 5
7.4 Description of parameters ............................................................................................................................90
7.4.1 Menu: Easy Setup.................................................................................................................................90
7.4.2 Menu: Device Info .................................................................................................................................93
7.4.3 Menu: Config. Device............................................................................................................................97
7.4.4 Menu: Display .....................................................................................................................................101
7.4.5 Menu: Input / Output ...........................................................................................................................103
7.4.6 Menu: Process Alarm..........................................................................................................................109
7.4.7 Menü: Communication ........................................................................................................................110
7.4.8 Menu: Diagnostics...............................................................................................................................115
7.4.9 Menu: Totalizer ...................................................................................................................................124
7.5 Alarm Simulation ........................................................................................................................................126
7.6 Software history..........................................................................................................................................128
7.6.1 Devices with HART protocol ...............................................................................................................128
7.6.2 Devices with PROFIBUS PA or FOUNDATION Fieldbus...................................................................128
8Extended diagnostic functions...............................................................................................................129
8.1 General.......................................................................................................................................................129
8.1.1 Detection of partial filling.....................................................................................................................129
8.1.2 Detection of gas bubbles 1) ................................................................................................................129
8.1.3 Detection of deposits on measuring electrodes 1)..............................................................................130
8.1.4 Conductivity monitoring 1) ..................................................................................................................130
8.1.5 Electrode impedance monitoring 1) ....................................................................................................131
8.1.6 Sensor measurements........................................................................................................................131
8.1.7 Trend...................................................................................................................................................132
8.1.8 Fingerprint ...........................................................................................................................................132
8.1.9 Checking the grounding ......................................................................................................................132
8.2 Checking the grounding .............................................................................................................................133
8.2.1 Performing the grounding check.........................................................................................................133
8.3 Recommended settings for diagnostic limit values ....................................................................................135
8.3.1 Limit values for the coil resistance ......................................................................................................135
8.3.2 Limit values for the electrode deposits................................................................................................136
8.3.3 Limit values for the electrode impedance ...........................................................................................136
8.3.4 Recommended settings for the Trend Logger ....................................................................................136
9Error messages ........................................................................................................................................137
9.1 Invoking the error description.....................................................................................................................137
9.2 Error states and alarms..............................................................................................................................138
9.2.1 Errors ..................................................................................................................................................138
9.2.2 Function check ....................................................................................................................................139
9.2.3 Operation outside of specifications (Off Spec) ...................................................................................141
9.2.4 Maintenance........................................................................................................................................142
9.3 Overview of error states and alarms ..........................................................................................................143
9.3.1 Error messages during commissioning...............................................................................................147
10 Maintenance..............................................................................................................................................149
10.1 Flowmeter sensor.......................................................................................................................................149
10.2 Gaskets ......................................................................................................................................................150
10.3 Replacing the transmitter or sensor ...........................................................................................................150
10.3.1 Transmitter ..........................................................................................................................................151
10.3.2 Flowmeter sensor................................................................................................................................152
10.3.3 Downloading the system data.............................................................................................................153
11 Spare parts list .........................................................................................................................................154
11.1 Fuses for transmitter electronics ................................................................................................................154
11.2 Spare parts for the compact design ...........................................................................................................154

Contents
6 FEX300, FEX500 OI/FEX300/FEX500-EN
11.3 Spare parts for remote design....................................................................................................................155
11.3.1 field-mount housing.............................................................................................................................155
11.3.2 Round field-mount housing .................................................................................................................156
11.3.3 Flowmeter sensor (Zone 2/Div 2)........................................................................................................156
11.3.4 Flowmeter sensor (Zone 1/Div 1)........................................................................................................157
12 Performance specifications ....................................................................................................................158
12.1 General.......................................................................................................................................................158
12.1.1 Reference conditions according to EN 29104 ....................................................................................158
12.1.2 Maximum measuring error ..................................................................................................................158
12.2 Reproducibility, response time ...................................................................................................................158
12.3 Transmitter .................................................................................................................................................158
12.3.1 Electrical properties.............................................................................................................................158
12.3.2 Mechanical properties.........................................................................................................................158
13 Functional and technical properties - ProcessMaster .........................................................................159
13.1 Flowmeter sensor.......................................................................................................................................159
13.1.1 Protection type according to EN 60529 ..............................................................................................159
13.1.2 Pipeline vibration according to EN 60068-2-6 ....................................................................................159
13.1.3 Installation length ................................................................................................................................159
13.1.4 Signal cable (for external transmitters only) .......................................................................................159
13.1.5 Temperature range .............................................................................................................................159
13.1.6 Material load........................................................................................................................................162
13.1.7 Flowmeter sensor................................................................................................................................163
14 Functional and technical properties - HygienicMaster ........................................................................164
14.1 Flowmeter sensor.......................................................................................................................................164
14.1.1 Protection type according to EN 60529 ..............................................................................................164
14.1.2 Pipeline vibration according to EN 60068-2-6 ....................................................................................164
14.1.3 Installation length ................................................................................................................................164
14.1.4 Signal cable (for external transmitters only) .......................................................................................164
14.1.5 Temperature range .............................................................................................................................164
14.1.6 Material load........................................................................................................................................166
14.1.7 Mechanical properties.........................................................................................................................167
15 Appendix ...................................................................................................................................................168
15.1 Other applicable documents.......................................................................................................................168
15.2 Approvals and certifications .......................................................................................................................168
15.3 Overview of parameter settings (factory settings)......................................................................................171
15.3.1 For Profibus PA version ......................................................................................................................171
16 Index ..........................................................................................................................................................173

Safety
OI/FEX300/FEX500-EN FEX300, FEX500 7
1 Safety
1.1 General information and notes for the reader
You must read these instructions carefully prior to installing and commissioning the device.
These instructions are an important part of the product and must be kept for future reference.
These instructions are intended as an overview and do not contain detailed information on all
designs for this product or every possible aspect of installation, operation and maintenance.
For additional information or if specific problems occur that are not discussed in these
instructions, contact the manufacturer.
The content of these instructions is neither part of any previous or existing agreement, promise
or legal relationship nor is it intended to change the same.
This product is built based on state-of-the-art technology and is operationally safe. It has been
tested and left the factory in perfect working order from a safety perspective. The information in
the manual must be observed and followed in order to maintain this state throughout the period
of operation.
Modifications and repairs to the product may only be performed if expressly permitted by these
instructions.
Only by observing all of the safety instructions and all safety/warning symbols in these
instructions can optimum protection of both personnel and the environment, as well as safe and
fault-free operation of the device, be ensured.
Information and symbols directly on the product must be observed. They may not be removed
and must be fully legible at all times.
Important (Notice)
• An additional document with Ex safety instructions is available for measuring systems that
are used in explosion hazardous areas.
• Ex safety information is an integral part of this manual. As a result, it is crucial that the
installation guidelines and connection values it lists are also observed.
The icon on the name plate indicates the following:

Safety
8 FEX300, FEX500 OI/FEX300/FEX500-EN
1.2 Intended use
This device is intended for the following uses:
• To transmit fluid, pulpy or pasty substances with electrical conductivity.
• To measure the flowrate of the operating volume or mass flow units (at constant pressure /
temperature), if a mass engeineering unit is selected.
The following items are included in the intended use:
• Read and follow the instructions in this manual.
• Observe the technical ratings; refer to the section 1.11 „Technical limit values“.
• Use only allowed liquids for measurement; refer to the section 1.12 „Allowed Fluids“.
1.3 Improper use
The following are considered to be instances of improper use of the device:
• Operation as a flexible adapter in piping, e.g., to compensate for pipe offsets, pipe vibrations,
pipe expansions, etc.
• As a climbing aid, e. g., for mounting purposes
• As a support for external loads, e. g., as a support for piping, etc.
• Adding material, e. g., by painting over the name plate or welding/soldering on parts
• Removing material, e. g., by spot drilling the housing
1.4 Target groups and qualifications
Installation, commissioning, and maintenance of the product may only be performed by trained
specialist personnel who have been authorized by the plant operator to do so. The specialist
personnel must have read and understood the manual and comply with its instructions.
Prior to using corrosive and abrasive materials for measurement purposes, the operator must
check the level of resistance of all parts coming into contact with the materials to be measured.
ABB Automation Products GmbH will gladly support you in selecting the materials, but cannot
accept any liability in doing so.
The operators must strictly observe the applicable national regulations with regards to
installation, function tests, repairs, and maintenance of electrical products.
1.5 Warranty provisions
Using the device in a manner that does not fall within the scope of its intended use, disregarding
this instruction, using underqualified personnel, or making unauthorized alterations releases the
manufacturer from liability for any resulting damage. This renders the manufacturer's warranty
null and void.

Safety
OI/FEX300/FEX500-EN FEX300, FEX500 9
1.6 Plates and symbols
1.6.1 Safety-/ warning symbols, note symbols
DANGER – <Serious damage to health / risk to life>
This symbol in conjunction with the signal word "Danger" indicates an imminent danger.
Failure to observe this safety information will result in death or severe injury.
DANGER – <Serious damage to health / risk to life>
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 possibly dangerous
situation. Failure to observe this safety information may 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 may result in death or severe injury.
CAUTION – <Minor injury>
This symbol in conjunction with the signal word “Caution“ indicates a possibly dangerous
situation. Failure to observe this safety information may result in minor or moderate injury.
This may also be used for property damage warnings.
NOTICE – <Property damage>!
The symbol indicates a potentially damaging situation.
Failure to observe this safety information may result in damage to or destruction of the product
and/or other system components.
IMPORTANT (NOTE)
This symbol indicates operator tips, particularly useful information, or important information
about the product or its further uses. It does not indicate a dangerous or damaging situation.

Safety
10 FEX300, FEX500 OI/FEX300/FEX500-EN
1.6.2 Name plate
Important (Notice)
An additional document with Ex safety instructions is available for measuring systems that are
used in explosion hazardous areas. As a result, it is crucial that the specifications and data it
lists are also observed.
1.6.2.1 Name plate for compact design
Fig. 1: Compact device
1 Model number (for more detailed information about
the technical design, refer to the data sheet or the
order confirmation)
2 Order no.
3 Meter size and nominal pressure rating
4 Material: Flange/lining/electrode
5 Client-specific TAG number (if specified)
6 Tmed = maximum permissible fluid temperature
T
amb = maximum permissible ambient temperature
7 Protection type according to EN 60529
8 Calibration value Qmax DN
9 Calibration value Ss (span)
Calibration value Sz (zero point)
10Communications protocol of transmitter
11 Software version
12Year of manufacture
13CE mark
14Serial number for identification by the manufacturer
15Supplementary information: EE = grounding
electrodes, TFE = partial filling electrode
16Accuracy to which the unit was calibrated (e.g., 0.2%
of rate)
17Excitation frequency of sensor coils
18Version level (xx.xx.xx)
19Label indicating whether the unit is subject to the
Pressure Equipment Directive (PED).
Information on the relevant fluid group.
Fluid group 1 = hazardous fluids, liquid, gaseous.
(Pressure Equipment Directive = PED).
If the pressure equipment is not subject to the
Pressure Equipment Directive 97/23/EC, it is
classified in accordance with SEP (= sound
engineering practice) as per Art. 3 Para. 3 of the PED.
If no such information is present, it means that the
device does not claim to comply with the requirements
of the Pressure Equipment Directive 97/23/EC. Water
supplies and connected equipment accessories are
classed as an exception in accordance with guideline
1/16 of Art. 1 Para. 3.2 of the Pressure Equipment
Directive.
Important (Notice)
Meters with 3A approval are labeled with an additional plate.

Safety
OI/FEX300/FEX500-EN FEX300, FEX500 11
1.6.2.2 Name plate for the remote design
Fig. 2: Remote design
1 Model number (for more detailed information about
the technical design, refer to the data sheet or the
order confirmation)
2 Order no.
3 Meter size and nominal pressure rating
4 Material: Flange/lining/electrode
5 Client-specific TAG number (if specified)
6 Tmed = maximum permissible fluid temperature
T
amb = maximum permissible ambient temperature
7 Protection type according to EN 60529
8 Calibration value Qmax DN
9 Calibration value Ss (span)
Calibration value Sz (zero point)
10Year of manufacture
11CE mark
12Serial number for identification by the manufacturer
13Supplementary information: EE = grounding
electrodes, TFE = partial filling electrode
14Accuracy to which the unit was calibrated (e.g., 0.2%
of rate)
15Excitation frequency of sensor coils
16Label indicating whether the unit is subject to the
Pressure Equipment Directive (PED).
Information on the relevant fluid group.
Fluid group 1 = hazardous fluids, liquid, gaseous.
(Pressure Equipment Directive = PED).
If the pressure equipment is not subject to the
Pressure Equipment Directive 97/23/EC, it is
classified in accordance with SEP (= sound
engineering practice) as per Art. 3 Para. 3 of the PED.
If no such information is present, it means that the
device does not claim to comply with the requirements
of the Pressure Equipment Directive 97/23/EC. Water
supplies and connected equipment accessories are
classed as an exception in accordance with guideline
1/16 of Art. 1 Para. 3.2 of the Pressure Equipment
Directive.
Important (Notice)
Meters with 3A approval are labeled with an additional plate.

Safety
12 FEX300, FEX500 OI/FEX300/FEX500-EN
1.6.2.3 Name plate for transmitter
Fig. 3: External transmitter (remote design)
1 Model number (for more detailed information about
the technical design, refer to the data sheet or the
order confirmation)
2 Order no.
3 Client-specific TAG number (if specified)
4 Tamb = maximum permissible ambient temperature
5 Protection type according to EN 60529
6Supply voltage
7Communications protocol of transmitter
8 Software version
9Version level (xx.xx.xx)

Safety
OI/FEX300/FEX500-EN FEX300, FEX500 13
1.7 Transport safety information
• Depending on the device, the center of gravity may not be in the center of the equipment.
• The protection plates or protective caps installed on the process connections of devices lined
with PTFE / PFA must not be removed until just before installation; to prevent possible
leakage, make sure that the liner on the flange is not cut or damaged.
1.8 Installation safety information
Observe the following instructions:
• The flow direction must correspond to the direction indicated on the device, if labeled.
• Comply with the maximum torque for all flange bolts.
• Install the devices without mechanical tension (torsion, bending).
• Install flange and wafer type units with coplanar counter flanges.
• Only install devices for the intended operating conditions and with suitable seals.
• Secure the flange bolts and nuts against pipeline vibrations.
1.9 Safety instructions for electrical installation
Electrical connections may only be established by authorized specialist personnel in
accordance with the electrical circuit diagrams.
The electrical connection information in the manual must be observed; otherwise, the type of
electrical protection may be adversely affected.
Ground the flowmeter and the sensor housing.
The line for the supply power must be installed according to the relevant national and
international standards. A separate fuse must be connected upstream and in close proximity to
each unit. The fuses must be identified accordingly. The rated current of the circuit breaker must
not exceed 10 A.
The unit has a protection class of I and overvoltage class II (IEC664).
The power supply and the electrical circuit for the coils of the flowmeter sensor are dangerous
and pose a contact risk.
The coil and signal circuit may be connected with the corresponding ABB flowmeter sensors
only. Use the supplied cable.
Only electrical circuits that do not pose a contact risk can be connected to the remaining signal
inputs and outputs.

Safety
14 FEX300, FEX500 OI/FEX300/FEX500-EN
1.10 Safety instructions for operation
During operation with hot fluids, contact with the surface may result in burns.
Aggressive fluids may result in corrosion or abrasion of the parts that come into contact with the
medium. As a result, pressurized fluids may escape prematurely.
Wear to the flange gasket or process connection gaskets (e.g., aseptic threaded pipe
connections, Tri-Clamp, etc.) may enable a pressurized medium to escape.
When using internal flat gaskets, these can become embrittled through CIP/SIP processes.
If pressure shocks exceeding the device's permissible nominal pressure occur continuously
during operation, this can have a detrimental effect on the device's service life.
Warning – Risk to persons!
Bacteria and chemical substances can contaminate or pollute pipeline systems and the
materials they are made of.
The appropriate installation conditions must be observed in order to achieve an installation
that complies with EHEDG requirements.
For an installation to comply with EHEDG requirements, the process connection/gasket
combinations created by the operator must always be made of parts that conform to EHEDG
stipulations (EHEDG Position Paper: "Hygienic Process connections to use with hygienic
components and equipment").
1.11 Technical limit values
The device is designed for use exclusively within the stated values on the name plate and within
the technical limit values specified in the data sheets.
The following technical limit values must be observed:
• The permissible operating pressure (PS) in the permissible temperature (TS) may not
exceed the pressure-temperature ratings.
• The maximum operating temperature may not be exceeded.
• The permitted operating temperature may not be exceeded.
• The housing protection system must be observed.
• The flowmeter sensor may not be operated in the vicinity of powerful electromagnetic fields,
e.g., motors, pumps, transformers, etc. A minimum spacing of approx. 1 m (3.28 ft) should
be maintained. For installation on or to steel parts (e.g., steel brackets), a minimum spacing
of approx. 100 mm (3.94 inch) should be maintained (based on IEC801-2 and IECTC77B).
1.12 Allowed Fluids
When measuring fluids, the following points must be observed:
• Fluids may only be used if, based on state-of-the-art technology or the operating experience
of the user, it is assured that chemical and physical properties of the components coming
into contact with the fluids (signal electrodes, ground electrodes, liners and, possibly,
process connections, protective plates or protective flanges) are not affected during the
operating life.
• Fluids with unknown properties or abrasive fluids may only be used if the operator can
perform regular and suitable tests to ensure the safe condition of the device.
• Observe the information on the name plate.

Safety
OI/FEX300/FEX500-EN FEX300, FEX500 15
1.13 Maintenance and inspection safety information
Warning – Risk to persons!
When the housing cover is open, EMC and protection against contact are suspended. There
are electric circuits within the housing which pose a contact risk.
The auxiliary power must be switched off before opening the housing cover.
Warning – Risk to persons!
The inspection screw (for draining condensate fluid) for devices ≥DN 450 can be under
pressure. The fluid which spurts out can cause severe injuries.
Depressurize pipes before opening the inspection screw.
Corrective maintenance work may only be performed by trained personnel.
• Depressurize the device and adjoining lines or containers before removing the device.
• Check whether hazardous materials are used as materials to be measured before opening
the device. Residual amounts of hazardous material may still be present in the device and
could escape when the device is opened.
• As far as provided in the scope of the operational responsibility, check the following items
through a regular inspection:
 the pressure-carrying walls / lining of the pressure device
 the measurement-related function
 the leak tightness
 the wear (corrosion)
1.14 Returning devices
Use the original packaging or suitably secure shipping containers if you need to return the
device for repair or recalibration purposes. Fill out the return form (see the Appendix) and
include this with the device.
According to EC guidelines for hazardous materials, the owner of hazardous waste is
responsible for its disposal or must observe the following regulations for shipping purposes:
All devices delivered to ABB Automation Products GmbH must be free from any hazardous
materials (acids, alkalis, solvents, etc.).
Rinse out and neutralize hazardous materials from all hollow spaces such as between meter
tube and housing. For flowmeters larger than DN 400, the service screw (for draining
condensate fluid) at the lower point of the housing must be opened to dispose of hazardous
substances and to neutralize the coil and electrode chamber. These activities must be
confirmed in writing using the return form.
Please
Please contact Customer Center Service acc. to page 2 for nearest service location.

Safety
16 FEX300, FEX500 OI/FEX300/FEX500-EN
1.15 Integrated management system
ABB Automation Products GmbH operates an integrated management system, consisting of:
• Quality management system to ISO 9001:2008
• Environmental management system to ISO 14001:2004
• Occupational health and safety management system to BS OHSAS 18001:2007 and
• Data and information protection management system
Environmental awareness is an important part of our company policy.
Our products and solutions are intended to have a minimal impact on the environment and on
people during manufacturing, storage, transport, use, and disposal.
This includes the environmentally-friendly use of natural resources. We conducts an open
dialog with the public through our publications.
1.16 Disposal
This product is manufactured from materials that can be reused by specialist recycling
companies.
1.16.1 Information on WEEE Directive 2002/96/EC (Waste Electrical and Electronic Equipment)
This product is not subject to WEEE Directive 2002/96/EC or relevant national laws
(e.g., ElektroG in Germany).
The product must be disposed of at a specialist recycling facility. Do not use municipal garbage
collection points. According to the WEEE Directive 2002/96/EC, only products used in private
applications may be disposed of at municipal garbage facilities. Proper disposal prevents
negative effects on people and the environment, and supports the reuse of valuable raw
materials.
If it is not possible to dispose of old equipment properly, ABB Service can accept and dispose of
returns for a fee.
1.16.2 RoHS Directive 2002/95/EC
With the Electrical and Electronic Equipment Act (ElektroG) in Germany, the European
Directives 2002/96/EC (WEEE) and 2002/95/EC (RoHS) are translated into national law.
ElektroG defines the products that are subject to regulated collection and disposal or reuse in
the event of disposal or at the end of their service life. ElektroG also prohibits the marketing of
electrical and electronic equipment that contains certain amounts of lead, cadmium, mercury,
hexavalent chromium, polybrominated biphenyls (PBB), and polybrominated diphenyl ethers
(PBDE) (also known as hazardous substances with restricted uses).
The products provided by ABB Automation Products GmbH do not fall within the current scope
of the directive on waste from electrical and electronic equipment according to ElektroG. If the
necessary components are available on the market at the right time, in the future these
substances will no longer be used in new product development.

Design and function
OI/FEX300/FEX500-EN FEX300, FEX500 17
2 Design and function
2.1 Measuring principle
Measurements performed by the electromagnetic flowmeter are based on Faraday’s law of
induction. A voltage is generated in a conductor when it moves through a magnetic field.
This principle is applied to a conductive fluid in the measuring tube through which a magnetic
field is generated perpendicular to the flow direction (see schematic).
The voltage induced in the fluid is measured by two electrodes located diametrically opposite
each other. This signal voltage UEis proportional to the magnetic induction B, the electrode
spacing D and the average flow velocity v.
Considering that the magnetic induction B and the electrode spacing D are constant values, a
proportionality exists between the signal voltage UEand the average flow velocity v. From the
equation for calculating the volume flowrate, it follows that the signal voltage is linearly
proportional to the volume flowrate: UE~ qv.
The induced voltage is converted by the transmitter to standardized, analog and digital signals.
G00005
1
2
3
Fig. 4: Electromagnetic flowmeter schematic
1Magnet coil
2Measuring tube in electrode plane
3Signal electrode
UESignal voltage
BMagnetic induction
DElectrode spacing
vAverage flow velocity
qvVolume flow
UE~ vDB


qv = v
D
4
2

UE~ qv

Design and function
18 FEX300, FEX500 OI/FEX300/FEX500-EN
2.2 Device designs
Important (Notice)
An additional document with Ex safety instructions is available for measuring systems that are
used in explosion hazardous areas. As a result, it is crucial that the specifications and data it
lists are also observed.
ProcessMaster / HygienicMaster is available in two series.
ProcessMaster / HygienicMaster 300 with basic functionality and ProcessMaster /
HygienicMaster 500 with extended functions and options. The following table gives an overview.
ProcessMaster HygienicMaster
FEP300 FEP500 FEH300 FEH500
Measuring accuracy
0.4 % (optional 0.2 %) of rate
X - X -
Measuring accuracy
0,3 % (optional 0.2 %) of rate
- X - X
Batch functions
Presetting counter, overrun correction,
external start/stop, batch end contact
- X - X
Other software functions
Mass units, editable totalizers,
X X X X
Two measuring ranges - X - X
Graphic display
Line recorder function
X X X X
Diagnostic functions
Detection of gas bubbles or deposits on
electrodes, conductivity monitoring,
temperature monitoring, finger print, trend
- X - X
Partially filled
Recognition through partial filling
electrode (TFE)
X X - -
Hardware options
• Ceramic carbide lining
• Wolfram carbide electrodes
• Double layer electrodes
- X - -
Hardware options
DN 1 ... 2
- - - X
Startup functions
Grounding check
- X - X
Fieldbus
PROFIBUS PA, FOUNDATION Fieldbus
X X X X
Verifications / Diagnostic tool
ScanMaster
X X X X

Design and function
OI/FEX300/FEX500-EN FEX300, FEX500 19
2.2.1 Design
An electromagnetic flowmeter system consists of a sensor and a transmitter. The sensor is
installed in the specified pipeline while the transmitter is mounted locally or at a central location.
2.2.2 Model with compact design
The transmitter and the flowmeter sensor form a single mechanical entity.
ProcessMaster HygienicMaster
Fig. 5
2.2.3 Model with remount mount design
The transmitter is mounted in a separate location from the flowmeter sensor. The electrical
connection between the transmitter and the sensor is provided by a signal cable.
Without a pre-amplifier, the maximum permissible signal cable length is 50 m (164 ft) with a
minimum conductivity of 5 µS/cm.
With a pre-amplifier, the maximum permissible signal cable length is 200 m (656 ft).
ProcessMaster HygienicMaster
Fig. 6

Transport and storage
20 FEX300, FEX500 OI/FEX300/FEX500-EN
3 Transport and storage
3.1 Inspection
Check the devices for possible damage that may have occurred during transport. Damages in
transit must be recorded on the transport documents. All claims for damages must be claimed
without delay against the shipper and before the installation.
3.2 Transport of flanged units smaller than DN 450
Warning – Danger of injuries due to slipping meter.
The center of gravity for the complete device may be higher than the lifting straps.
Make sure the device has not rotated or slipped unintentionally during transport. Support the
meter laterally.
For transport of flanged units smaller than DN 450 use a lifting strap. Wrap the straps around
both process connections when lifting the device. Avoid chains since these may damage the
housing.
Fig. 7: Transport of flanged units smaller than DN 450