ABB HART FEP300 Installation and operation manual

CI/FEP300/FEH300-EN ProcessMaster / HygienicMaster
Commissioning Instruction
Electromagnetic Flowmeter
FEP300/FEH300

Neu
Electromagnetic Flowmeter
ProcessMaster / HygienicMaster
Commissioning Instruction - EN
CI/FEP300/FEH300-EN
08.2008
Manufacturer:
ABB Automation Products GmbH
Dransfelder Straße 2
D-37079 Göttingen
Germany
Tel.: [phone]
Fax: [phone]
[email protected]
© Copyright 2008 by ABB Automation Products GmbH
Subject to change without notice
This document is protected by copyright. It assists the user with the safe and efficient operation of the
device. The contents may not be copied or reproduced in whole or in excerpts without prior approval of
the copyright holder.
Contents

Contents
2 - EN ProcessMaster / HygienicMaster CI/FEP300/FEH300-EN
1Safety....................................................................................................................................................................4
1.1 General Safety Information ............................................................................................................................4
1.2 Symbols and warnings ...................................................................................................................................4
1.3 Intended use...................................................................................................................................................5
1.4 Improper use ..................................................................................................................................................5
1.5 Technical limit values .....................................................................................................................................5
1.6 Allowed Fluids ................................................................................................................................................6
1.7 Operator liability .............................................................................................................................................6
1.8 Personnel qualification ...................................................................................................................................6
1.9 Transport safety information ..........................................................................................................................6
1.10 Installation safety information.........................................................................................................................7
1.11 Electrical installation safety information .........................................................................................................7
1.12 Operating safety information ..........................................................................................................................7
2Transport..............................................................................................................................................................8
2.1 Inspection .......................................................................................................................................................8
2.2 Transport of flanged units smaller than DN 450 ............................................................................................8
2.3 Transport of flanged units larger than DN 400...............................................................................................8
3Installation............................................................................................................................................................9
3.1 General information on installation.................................................................................................................9
3.1.1 Supports for meter sizes larger than DN 400..........................................................................................9
3.1.2 Mounting the measuring tube................................................................................................................10
3.2 Torque information .......................................................................................................................................11
3.2.1 Flanged units ProcessMaster and HygienicMaster ..............................................................................11
3.2.2 Wafer type unit (HygienicMaster)..........................................................................................................13
3.2.3 Variable process connections (HygienicMaster)...................................................................................13
3.3 Information on 3A conformity .......................................................................................................................14
3.4 Installation Requirements.............................................................................................................................15
3.4.1 Electrode axis........................................................................................................................................15
3.4.2 In- and outlet pipe sections ...................................................................................................................15
3.4.3 Vertical connections ..............................................................................................................................15
3.4.4 Horizontal connections..........................................................................................................................15
3.4.5 Free inlet or outlet .................................................................................................................................15
3.4.6 Strongly contaminated fluids.................................................................................................................15
3.4.7 Installation in the vicinity of pumps .......................................................................................................16
3.4.8 Installing the high temperature design..................................................................................................16
3.4.9 Installation in pipelines with larger nominal diameters..........................................................................16
3.5 Ground..........................................................................................................................................................17
3.5.1 General information on ground connections.........................................................................................17
3.5.2 Metal pipe with fixed flanges.................................................................................................................17
3.5.3 Metal pipe with loose flanges................................................................................................................18
3.5.4 Non-metallic pipes or pipes with insulating liner ...................................................................................18
3.5.5 Sensor type HygienicMaster .................................................................................................................19

Contents
CI/FEP300/FEH300-EN ProcessMaster / HygienicMaster EN - 3
3.5.6 Ground for devices with hard rubber lining ...........................................................................................19
3.5.7 Ground for devices with protective plates.............................................................................................19
3.5.8 Ground with conductive PTFE grounding plate ....................................................................................19
3.6 Preparing and routing the signal and magnet coil cable..............................................................................20
3.6.1 Protection class IP 68 ...........................................................................................................................22
3.7 Connecting the transmitter ...........................................................................................................................24
3.7.1 Connecting the supply power................................................................................................................24
3.7.2 Transmitter ............................................................................................................................................25
3.7.3 Electrical connection diagram ...............................................................................................................26
4Startup Operation..............................................................................................................................................28
4.1 Preliminary checks prior to start-up..............................................................................................................28
4.2 Operation......................................................................................................................................................28
4.2.1 Menu navigation....................................................................................................................................28
4.2.2 Process display .....................................................................................................................................29
4.3 Commissioning the unit................................................................................................................................30
4.3.1 Downloading the system data...............................................................................................................30
4.3.2 Parametrizing via the "Easy Set-up" menu function .............................................................................31
4.3.3 Changing to the information level .........................................................................................................34
4.4 Flowmeter sizes. flow range.........................................................................................................................35
5Appendix ............................................................................................................................................................36
5.1 Additional documents...................................................................................................................................36
5.2 Permits and certifications .............................................................................................................................36

Safety
4 - EN ProcessMaster / HygienicMaster CI/FEP300/FEH300-EN
1 Safety
1.1 General Safety Information
The “Safety” chapter provides an overview of the safety aspects to be observed for the
operation of the device.
The device is built based on state-of-the-art technology and is operationally safe. It was tested
and left the factory in a proper state. The requirements in the manual as well as the
documentation and certificates must be observed and followed in order to maintain this state for
the period of operation.
The general safety requirements must be complied with completely during operation of the
device. In addition to the general information, the individual chapters of the manual contain
descriptions about processes or procedural instructions with specific safety information.
Only the observance of all safety information enables the optimal protection of personnel as well
as the environment from hazards and the safe and trouble-free operation of the device.
1.2 Symbols and warnings
Danger – <Serious damage to health / risk to life>
One of these symbols in conjunction with the “Danger“ warning indicates an imminent danger.
If it is not avoided, death or serious injury will result.
Warning – <Bodily injury>
The symbol in conjunction with the “Warning“ message indicates a possibly dangerous
situation. If it is not avoided, death or serious injury could result.
Caution – <Slight injuries>
The symbol in conjunction with the “Caution“ message indicates a possibly dangerous
situation. If it is not avoided, slight or minor injury can result. May also be used for property
damage warnings.
Notice – <Property damage>
The symbol indicates a possibly damaging situation. If it is not avoided, the product or
something in its area can be damaged.
Important
The symbol indicates operator tips or especially useful information. This is not a message for a
dangerous or damaging situation.

Safety
CI/FEP300/FEH300-EN ProcessMaster / HygienicMaster EN - 5
1.3 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 “Technical limit values”.
• Use only allowed liquids for measurement; refer to the section “Allowed fluids”.
1.4 Improper use
The following uses of the device are prohibited:
• Operation as a flexible adapter in piping, e.g., to compensate for pipe offsets, pipe vibrations,
pipe expansions, etc.
• Use as a climbing aid, e.g., for assembly purposes.
• Use as a support for external loads, e.g., as a support for pipes, etc.
• Material gain, e.g., by painting over the name plate or adding parts by welding / soldering.
• Material loss, e.g., by drilling the housing.
1.5 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).

Safety
6 - EN ProcessMaster / HygienicMaster CI/FEP300/FEH300-EN
1.6 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.
1.7 Operator liability
Before the use of corrosive and abrasive measuring fluid, the operator must clarify the
resistance of all parts that come into contact with the fluid to be measured. ABB will gladly
support you with the selection, however, cannot accept any liability.
The operators must strictly observe the applicable national regulations in their countries with
regards to installation, function tests, repairs, and maintenance of electrical devices.
1.8 Personnel qualification
The installation, commissioning and maintenance of the device may only be carried out through
trained specialist personell authorized by the plant operator. The specialist personnel must have
read and understood the manual and comply with its instructions.
1.9 Transport safety information
Observe the following information:
• Depending on the device, the center of gravity may not be in the center of the equipment.
• The protective plates or dust caps mounted at the process connections of devices equipped
with PTFE/PFA may only be removed before installation.
To prevent possible leakage, make sure that the liner on the flange is not cut or damaged.

Safety
CI/FEP300/FEH300-EN ProcessMaster / HygienicMaster EN - 7
1.10 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.
1.11 Electrical installation safety information
The electrical connection may only be performed by authorized specialists according to the
electrical plans.
Comply with electrical connection information in the manual. Otherwise, the electrical protection
can be affected.
Ground the flowmeter and 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 unit has a protection class of I and
overvoltage class II (IEC664).
The power supply and the electrical circuit for the coils of the sensor are dangerous and pose a
contact risk.
The coils and signal circuit can be connected with ABB 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.
1.12 Operating safety information
During operation with hot fluids, contact with the surface may result in burns.
Aggressive or corrosive fluids may result in damage to the parts which contact the fluid. As a
result, pressurized fluids may escape prematurely.
A pressurized fluid may escape due to wear on the flange seal or process connection gaskets
(e. g. aseptic threaded pipe connections, Tri-Clamp, etc.).
When using internal flat gaskets, these can become embrittled through CIP/SIP processes.

Transport
8 - EN ProcessMaster / HygienicMaster CI/FEP300/FEH300-EN
2 Transport
2.1 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.
2.2 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. 1: Transport of flanged units smaller than DN 450
2.3 Transport of flanged units larger than DN 400
Notice - Potential damage to device!
Use of a forklift to transport the device can bend the housing and damage the internal magnet
coils.
Flanged units may not be lifted at the middle of the housing when transporting via forklift.
Flanged units may not be lifted by the terminal box or at the middle of the housing. Use only the
eye bolts on the device to lift and install it in the pipeline.
Fig. 2: Transport of flanged units larger than DN 400