ABB MagMaster User manual

Electromagnetic Flowmeters
MagMasterTM
Cenelec/ATEX
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Instruction Manual
IM/MM–SF_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 plants operated by the Company, and is indicative of our
dedication to quality and accuracy.
EN 29001 (ISO 9001)
Lenno, Italy – Cert. No. 9/90A
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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. Normal safety precautions must be taken to avoid the possibility of an accident occurring when operating
in conditions of high pressure and/or temperature.
5. Chemicals must be stored away from heat, protected from temperature extremes and powders kept dry.
Normal safe 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.
Electrical Safety
This instrument complies with the requirements of CEI/IEC 61010-1:2001-2 "Safety requirements for electrical
equipmentformeasurement,control,andlaboratoryuse".IftheinstrumentisusedinamannerNOTspecifiedbythe
Company, the protection provided by the instrument may be impaired.
Symbols
One or more of the following symbols may appear on the instrument 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

1
CONTENTS 1 INTRODUCTION
1 INTRODUCTION........................................ 1
2 MECHANICAL INSTALLATION ................2
2.1 Unpacking .........................................3
2.2 Installation Conditions.......................3
2.3 Mechanical Installation......................5
2.3.1 Transmitters..........................5
2.3.2 Sensors.................................5
3 ELECTRICAL INSTALLATION ................. 5
3.1 Grounding..........................................5
3.2 Cables ...............................................6
3.2.1 Cable
(Remote Versions only) ........6
3.2.2 Cable (Alternative Type –
North American Wiring
Practice)................................7
3.2.3 Cable Glands
(IEC Installation Practice) ....7
3.2.4 Conduit Adapters
and Cable Glands
(North American – 0.5in) ......8
3.3 Connection Requirements ................8
3.3.1 Sensors................................. 8
3.3.2 Transmitters
(All versions).......................10
3.3.3 MagMaster-CalMaster
Adapter ............................... 11
3.4 Input/Output Connections ...............12
3.4.1 Frequency Outputs.............12
3.4.2 PLC Interface......................12
3.4.3 Alarm Outputs.....................13
3.4.4 Contact Input ......................13
3.4.5 Current Output....................14
3.4.6 Computer Connection ........15
3.4.7 Power Supply
Connections........................16
4 STARTUP AND OPERATION .................17
4.1 Startup .............................................17
APPENDIX A – ENVIRONMENTAL
PROTECTION ................................................19
APPENDIX B – MAGMASTER BLOCK
DIAGRAM.......................................................20
MagMasterTM is a range of high performance
electromagnetic flowmeters for the
measurement of electrically conductive fluids
and slurries, and is normally supplied as a
calibrated system, with the transmitter, factory
configured, to a supplied full-bore or insertion
probe sensor.
A wide range of options is available to suit most
applications, including:
Integral or remote transmitter.
Glass loaded polypropylene or aluminium
transmitter housing.
Combined HartTM and Keypadsupport in
the aluminium housing transmitter.
Flanged or wafer style sensors.
Insertion Probes.
Approved Versions, including:
Hazardous area operation.
Hygienic.
HARTTM communication protocol.
Warning.
For MagMaster Approved /Hazardous
Versions see the full installation manual.
Warning.
• Installation and maintenance must only
be carried out by suitably trained
personnel.
• All relevant sections of this manual must
be read before selecting a location.
• Safety requirements of this equipment,
any associated equipment and the local
environment must be taken into
consideration.
• The installation and use of this
equipment must be in accordance with
relevant national and local standards.

2
Allow room to
read display
>5 x pipe dia.
minimum
>2 x pipe dia.
minimum
Flow Direction
60°C (140°F)
Maximum
–20°C (–4°F)
Minimum
2 MECHANICAL INSTALLATION
2.1 Unpacking
2.2 Installation Conditions
Fig. 2.1 Unpacking
Fig. 2.2 Spillage
Fig. 2.3 Lagging (High Temperature)
Fig. 2.4 Siting
Fig. 2.5 Vibration
Fig. 2.6 Localised Heat
Fig. 2.7 Straight Pipe Requirements
Fig. 2.8 Fluid Level
Fig. 2.9 Within Temperature Limits

3
IP65
(NEMA 4)
80°C (176°F)
Maximum !
–10°C (14°F)
Minimum
Backfill
Metal
Protection
Plate
Supports
Supports
2 MECHANICAL INSTALLATION…
Fig. 2.10 Cable Routing
Fig. 2.11 Within Environmental Rating
Fig. 2.12 Underground
Fig. 2.13 Above Ground
Fig. 2.14 Temperature Difference
Fig. 2.15 Shade

4
162mm (6.35in)
214mm
(8.43in)
69mm (2.72in)
(Fixing Centres)
232mm (9.13in)
(Fixing Centres)
32mm
(1.26in)
3 Fixing Holes,
6.5mm (1/4in) Diameter
Allowance for
cable bends
200mm (8in)
Gasket same size as pipe
Fit gaskets
PTFE
Metal
face
Gasket
Metal
face PTFE
Gasket
<15mm bore sensors
…2 MECHANICAL INSTALLATION
2.3 Mechanical Installation
2.3.1 Transmitters
2.3.2 Sensors
Caution
• Do NOT exceed the maximum working
pressure marked on the equipment.
• Use stainless steel (austenitic) bolts,
studs and nuts for flanged sensors below
200mm.
Fig. 2.16 Dimensions
Fig. 2.17 Gasket Fitting
Fig 2.18 WaferType Sensors
Caution. Do not overtighten fixings,
especially on an uneven surface.
Caution. For wafer type sensors of
<15mm bore, the fluid seal must be
madeagainstthe PTFE.Otherwiseuse
a full face gasket.

5
Insulating Sleeve
and Washer
(not provided)
Supplied Bonding Cables Insulated connecting wire
(not included). Must be
adequately rated to carry
cathodic currents.
Gasket Gasket
Grounding Ring
Grounding Rings Common Ground
(Plant bonding)
>4mm
2
(<10 AWG)
Copper Wire
Detail of grounding
rings required for
BOTH flanges
Wafer Type Sensors
>4mm
2
(<10AWG)
Copper Wire
Common Ground
(Plant bonding)
Supplied Bonding Cables
3 ELECTRICAL INSTALLATION
Fig. 3.1 Pipelines
Fig. 3.2 Pipelines with Cathodic Protection
3.1 Grounding (Fig. 3.1, 3.2)

6
Filler
Red wire (CD1)
Optional Steel Wire Armour
and submersible overjacket
Yellow wire (CD2)
Violet wire (SIG GND)
Grey Coaxial Core (SIG2)
Inner Conductor (SIG2)
Inner Insulation (Pink)
Conductive Layer (Black)
Primary Screen (DS2)
Insulation (Grey)
Foil Secondary Screen
White Coaxial Core (Sig1)
Inner Conductor (Sig 1)
Inner Insulation (Blue)
Conductive Layer (Black)
Primary Screen (DS1)
Insulation (White)
Foil Secondary Screen
Ground Wire (ESCREEN)
Overall Foil Screen
654
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nc
h
es 321
0
0
50
Millimetres
100
150
Overjacket Armour
Sheath Ground wire sleeved,
to post. (Ground)
Red (CD1) Yellow (CD2)
Pink (SIG2)
White
Grey
Screen (DS2)
Screen (DS1)
Blue (SIG1)
Violet (SIG GND)
…3 ELECTRICAL INSTALLATION
Fig. 3.3 Cable Identification
Fig. 3.4 Cable Preparation
3.2 Cables
3.2.1 Cable (Remote Versions only)

7
Signal Core/Wires
Inner Insulation (Natural/White)
Conductive Layer (Black)
Screen
Insulation (Black)
Foil Screen
Signal Core/Wires
Inner Insulation (Natural/White)
Conductive Layer (Black)
Screen
Insulation (White)
Foil Screen
Red
Black Green/Yellow Outer Jacket
Outer Drain Wire
Screen
Yellow
Black Coaxial Core/Wires White Coaxial Core/Wires
Cable - Part No. STT3350
Red
Yellow
Outer
Insulation Length for
Probe Head Length for
Transmitter
Black covered coax
Inner to SIG2. Screen to DS2
Black to SIG GND
White covered coax
Inner to SIG1. Screen to DS1
Overall screen drain
wire to ESCRN
54
Inches
321
0
0
50
Millimetres
100
'O'-Ring
3 ELECTRICAL INSTALLATION…
Warning.
• Rigid conduit must not be fitted to the
transmitter.
• Transmitter conduit adaptors must
incorporate a face seal.
Fig. 3.5 Cable Identification (North American Wiring Practice)
Fig. 3.6 Cable Preparation (North American Wiring Practice)
Fig. 3.7 Cable Gland
(IEC Installation Practice)
3.2.2 Cable (AlternativeType – North American Wiring Practice)
3.2.3 Cable Glands (IEC Installation Practice)

8
Ferrule
Outer Nut
Seal
(Present in
O.Z. Gedney
Fittings)
Alternative
Face Seal
Face
Seal
Hub
Fittings vary
slightly for
different makes
Outer Nut
Alternative
Face Seal
Face
Seal
Hub
Illustration
typical for
O.Z.Gedney
Conduit Adapters
Cable Glands
Power
Input/Output
Sensor
Transmitter
…3 ELECTRICAL INSTALLATION
3.2.4 Conduit Adapters and Cable Glands (North American – 0.5in)
3.3 Connection Requirements
The transmitter and sensor are supplied as a
matched system. Check serial numbers to
ensure they are matched.
3.3.1 Sensors
Remote sensors are usually supplied with an
integral cable and potted connections. If the
sensor has been supplied unpotted, connections
must also be made to the sensor terminal box
and then potted on completion with the supplied
potting material – See Appendix A.
Fig. 3.8 Conduit Adapters and Cable Glands
Fig. 3.9 Connection Requirements