ABB MagMaster User manual

Electromagnetic Flowmeters
MagMasterTM
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Approved
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
R
E
G
I
S
T
E
R
E
D
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
I
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

9
Note. If link is fitted, do NOT remove
––7 Screen
––6 Pink
––5 Blue
––4 Screen
––3 Violet
––2 Yellow
––1 Red
White
coaxial
Grey
coaxial
Ground Wire
(sleeved)
1
3
2
7
ESCRN
CD1
CD2
SIG GND
DS1
SIG1
SIG2
DS2
Red
Yellow
Screen
Pink
Blue
Screen
Violet
White Coaxial
Ground Wire
(sleeved)
Gray Coaxial
Standard Terminal Box Alternative Terminal Box
ESCRN
CD1
CD2
SIG GND
DS1
SIG1
SIG2
DS2
Red
Yellow
Screen
Pink
Blue
Screen
Black
White Coaxial
Cable
Outer Screen
(sleeved)
Note. If link is fitted, do NOT remove
Black Coaxial
Cable
Green/Yellow (Ground)
3 ELECTRICAL INSTALLATION…
Caution. (Remote versions)
• Remove any exposed black conductive layer from under coaxial screens.
• Make connections only as shown.
• Sleeve all bare wiring.
• Twist RED and YELLOW cores lightly together.
• Twist WHITE and GREY coaxial cables lightly together.
• Maintain Environmental Protection at all times.
• Conduit connections must provide cable entry sealing.
Information. (Remote versions)
• Refer to ENVIRONMENTAL PROTECTION (Appendix A).
• Internal appearance of Terminal Box may vary from that shown.
North American Wiring Practice
Fig. 3.10 Sensor Terminal Box Connections (Remote version)
Fig. 3.11 Sensor Terminal Box Connections (North American Wiring Practice)

10
2
2
...and
slide off
4
Slacken
captive
screws
R
emove
Protection
Cover
Pull out
slightly...
Slide
down
3
1
DS 2
IC 2 CD 1 CD 2
SIG GND DS 1 SIG 1
Grey Coax
Pink Inner (SIG 2)
Screen (DS 2)
Red
(CD 1)
Yellow
(CD 2) White Coax
Blue Inner (SIG 1)
Screen (DS 1)
Drive
Connections
Ground Wire
(Safety Earth)
Violet Signal
Connections
…3 ELECTRICAL INSTALLATION
3.3.2 Transmitters (All versions)
Caution. Unused
cable entries must
be blanked with
the permanent
blanking plugs
supplied with the
transmitters.
Caution.
• Remove any exposed black conductive layer from the inner insulation of both coaxial
cables.
• Substitute sensor cable of any kind is not acceptable.
• Do not make connections except as shown.
• Twist cable pairs together as shown.
• Sleeve ALL bare wires.
• Sensor cable may only be joined using company supplied junction box -
available separately.
Fig. 3.12 Transmitter ConnectionTerminal access
Fig. 3.13 Sensor Cable Connections at theTransmitter (Remote version)

11
DS 2
IC 2 CD 1 CD 2
SIG GND DS 1 SIG 1
Black Coax
Inner (SIG 2)
Screen (DS 2)
Red
(CD 1)
Yellow
(CD 2) White Coax
Blue Inner (SIG 1)
Screen (DS 1)
Drive
Connection
Cable Screen Connections
Drain Wire (ESCRN)
Signal
Connection
Gnd
Connection Black (SIG GND)
CD1 CD2 GROUND
White
Caution. Remove any exposed
black conductive layer from the
inner insulation of both coaxial
cables
Violet
Ground Wire
Sensor Cable
Adaptor Plug
Yellow
Red Blue
Pink
Grey
SIG GND DS 1 SIG 1
SIG 2
DS 2
3 ELECTRICAL INSTALLATION…
3.3.3 MagMaster-CalMaster Adapter
When a MagMaster Transmitter is fitted with an adaptor board for use with a CalMaster Verification
Unit, wiring from the sensor to this adaptor board is shown in the following diagram.
To wire the adaptor plug, carefully pull off the plug from the adaptor board, connect the wires, using
only a screwdriver with a 2.5mm blade to tighten the terminal screws, and replace the plug.
North American Wiring Practice
Fig 3.15 Fitting the Sensor Wiring onto the Adaptor
Fig. 3.14 Sensor Cable Connections at the Transmitter (North American Wiring Practice)

12
Forward Flow
d.c.
supply
Reverse Flow
Counter/Totalisers
Electromechanical
Connections
Telemetry, Electronic
Counters etc.
and/or
and/or
Counter/Totalisers
Forward Flow
Reverse Flow
F OUTA
F OUT B
PLS0V
F OUTA
F OUT B
PLS0V
123456
123456
123456
123456
MagMaster Transmitter
F OUTA
F OUT B
PLS0V
Typically
1kΩ1W
PLC – Common –ve
PLC – Common +ve
F OUTA
F OUT B
PLS0V
+
–
Rev +
PLC
Fwd +
+
–
Rev –
PLC
Fwd –
d.c.
supply
d.c. common
d.c.
supply
…3 ELECTRICAL INSTALLATION
Fig. 3.16 Frequency Output Connections
Fig. 3.17 Frequency Output Connections
3.4.1 Frequency Outputs – Fig. 3.16 3.4.2 PLC Interface – Fig. 3.17
3.4 Input/Output Connections
Caution.
• Refer to SPECIFICATION SHEET for Input/Output ratings.
• Inductive loads must be suppressed or clamped to limit voltage swings
• Capacitive loads must be inrush current limited.
• Hazardous area requirements are not considered in the following pages.
Note. The connection terminal markings in the metal housed transmitter are identical to those in
the standard transmitter as shown in this section. However, the supply connection in the former
is made using a non-reversible plug (provided).

13
ALARM1
ALARM2
PLS0V
Information.
Relay and Timer Switch shown for example
only. Connect as required.
Alarms MagMaster Transmitter
ALARM1
ALARM2
PLS0V
MagMaster Transmitter
and/or
Alarm 2
+
Alarm 1
d.c.
supply
Relay
Timer
Switch
R
Relays and Timers
Volt-free Contact
MagMaster Transmitter
+
Voltage Signal or Logic Signal
PLS0V
EXT I/P –
MagMaster Transmitter
Open Collector (or Grounded Contact)
PLS0V
EXT I/P –
MagMaster Transmitter
50.0
47.5
+
–
EXT I/P + EXT I/P –
EXT I/P +
ALARM 2
MagMaster Transmitter
Using an Alarm for Automatic
Range Change
Switch
EXT I/P +
EXT I/P – Switch
5V d.c. supply
3 ELECTRICAL INSTALLATION…
3.4.3 Alarm Outputs – Fig. 3.18
Information.
• Inductive loads may be suppressed by diodes (D) – 1N4004 or similar.
• Inrush currents are limited to 1 Amp by resistor R – e.g. 27Ω1W for 24V systems.
• Operation of outputs is programmable – see Configuration Manual for details.
• Frequency and Alarm outputs share a common return with contact input.
• External isolators not normally required, as the pulse, alarm and contact circuits are electrically
separated from all other Magmaster connections.
3.4.4 Contact Input – Fig 3.19
Fig. 3.18 Alarm Output Connections
Fig. 3.19 Contact Input Connections

14
IC2 IC+
IC –
IC+ IC– IC2 IC–
HART connections
where applicable
MagMaster Transmitter
Common
+ve
Normal Alternative
Information. For Multidrop HART installations, remove 'HART Link' and connect HART systems
directly to IC2: this allows the analog output function to be retained.
A1 100.0 °C
BOILER 6 TEMPERATURE
HART link
IC2 IC+
IC –
A1 100.0 °C
BOILER 6 TEMPERATURE
IC– IC2
HART connections
(where applicable)
MagMaster Transmitter
Common
Reverse +ve + HART
Information. Multidrop HART mode cannot be used with this configuration.
A1 100.0 °C
BOILER 6 TEMPERATURE
Receiver No. 2 – Reverse
Receiver No. 1 – Forward
Forward +ve
…3 ELECTRICAL INSTALLATION
3.4.5 Current Output – Fig. 3.20 and 3.21
Information.
• Output is fully programmable – see Programming Guide.
• Output is electrically separated from all other MagMaster connections.
• External isolators are not normally required and may significantly limit accuracy if used.
Fig. 3.20 Current Output Connections: Standard
Fig. 3.21 Current Output Connections: Dual Current Option

15
MagMaster
Transmitter
TX - SIG
TX + SIG
0VC
RX - SIG
RX + SIG
MagMaster
Transmitter
Link
TX - SIG
TX + SIG
0VC
RX - SIG
RX + SIG
MagMaster
TERMINALS
TX-SIG
TX+SIG
RX-SIG
RX+SIG
0VC
–
–
–
RS422 Connection
NAME
RX DATA -
RX DATA +
TX DATA -
TX DATA +
SIGNAL GROUND
DCD
DTR
DSR
APPLE Connector
(8 Pin MC)
5
8
3
6
4
7
1
2
CONNECT TO
Link
together Link together
9-Pin
PC
Connector
2
–
3
5
(linked)
4link
6together
7link
8together
MagMaster
TERMINALS
TX-SIG
TX+SIG
RX-SIG
RX+SIG
0VC
–
–
–
–
CONNECT TO
RS232
Name
RXD
–
TXD
GND
(linked)
DTR link
DSR together
RTS link
CTS together
25-Pin
PC
Connector
3
–
2
7
(linked)
20 link
6together
4link
5together
Hygienic
Adaptor
Cable
Red
–
Blue
Yellow
Green
–
–
–
–
3 ELECTRICAL INSTALLATION…
3.4.6 Computer Connection – Fig. 3.22 and 3.23
Information. RS422/423 option is electrically isolated from all other MagMaster connections.
Fig. 3.22 RS 422 Connections (Balanced)
Fig. 3.23 RS 423 Connections (Single Ended or RS 232)

16
SUPPLY 95V —240V ac
A.C power via a suitable
isolator and fuse
Neutral (N/L2) to N
N
L
>4mm
2
(<10 A.W.G.)
Copper Wire
External
Internal
Line (L/L1) to L
Transmitter Label
SUPPLY 11V —40V dc (Max)
DC Supply
Negative to –
–
+
>4mm
2
(<10 A.W.G.)
Copper Wire
External
Internal
Positive to +
Transmitter Label
…3 ELECTRICAL INSTALLATION
3.4.7 Power Supply Connections – Fig. 3.24 and 3.25
Warning.
•DISCONNECT THE SUPPLY FROM ANY CABLES BEING TERMINATED ON THE
TRANSMITTER.
•Electrical installation and earthing (grounding) must be in accordance with relevant national
and local standards.
•Ensure that the cover of the metal housed transmitter is never cross threaded. The threads are
greased (as supplied).
•Ensure that the grease is in good condition when fitting the cover, and replenish as required
with a grease suitable for aluminium threads.
Fig. 3.24 Power Supply Connections (A.C.VersionTransmitter)
Fig. 3.25 Power Supply Connections (D.C.VersionTransmitter)

17
Magnetic
Wand
MagMaster Transmitter
Local Display Area
>43567 Ltr
12.328Ltr/s
>43567 Ltr
12.328Ltr/s
Icons where Magnet
is applied
4 STARTUP AND OPERATION
Warning.
•Ensure Plant Safety while configuring, at
all times.
•The 9-way D-Type Serial Link is not
isolated. Ensure that it is NOT connected
topowerearth (ground),withcathodically
protected systems.
4.1 Startup
Switchonthepower supply totheflowmeter, and
ifatransmitterwithdisplay hasbeenordered, the
flowratewill beshownon thedisplayas shownin
Fig. 4.1 or 4.2.
Sequential application of the provided magnetic
wand to the left hand icon in the transmitter
display area, or by pressing the button on
the keypad versions or the remote display, steps
the display through the following sequence:
% (Flow Rate % of Range)
> (Forward flow total value)
< (Reverse flow total value)
* (Net flow total value)
Alm (Active alarms)
Vel (Flow Velocity in m/s or ft/s)
Any alarms are displayed sequentially if more
than one alarm is present.
Application of the wand to the right hand icon, or
pressing the keypad button, resets the
totaliser display, if this facility is enabled.
Information.
•For the use of local or remote serial
communication, and configuration, see
the Quick Reference Programming
Guide or the main MagMaster manual.
•For all versions supporting HARTTM, see
the main MagMaster manual.
Fig. 4.1 Location of Controls (Non-KeypadVersion)

18
MagMaster
32.8
Ltr/s
>42315
12.328
Ltr/s
>43567
…4 STARTUP AND OPERATION
Fig. 4.2 Location of Controls (KeypadVersions)