ABB MagMaster User manual

Electromagnetic Flowmeters
MagMasterTM
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Instruction Manual
IM/MM/SF_8
®

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
Sonehouse, U.K.
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 equipment for
measurement, control, and laboratory use". If the instrument is used in a manner NOT specified by the 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
0255

1
CONTENTS
1 INTRODUCTION ........................................ 1
2MECHANICAL INSTALLATION .................. 2
2.1 Unpacking .......................................... 2
2.2 Installation Conditions ......................... 2
2.3 Mechanical Installation ........................ 4
2.3.1 Transmitters ........................... 4
2.3.2 Sensors ................................. 4
3ELECTRICAL 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 Alternate
Wiring Configuration ............. 12
3.4 Input/Output Connections ................. 12
3.4.1 Frequency Outputs .............. 13
3.4.2 Alarm Outputs ...................... 13
3.4.3 PLC Interface ....................... 13
3.4.4 Contact Input ....................... 14
3.4.5 Current Output ..................... 15
3.4.6 Computer Connection .......... 16
3.4.7 Power Supply Connections .. 17
3.4.8 Profibus Connections ........... 18
4STARTUP AND OPERATION ................... 19
4.1 Startup ............................................. 19
APPENDIX A – ENVIRONMENTAL
PROTECTION ................................................. 21
SPECIFICATION ............................................. 22
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.
Insertion Probes.
Approved Versions, including:
Hazardous area operation.
HARTTM communication protocol.
PROFIBUS DP communication protocol.
Warning. For MagMaster Approved /
Hazardous Versions read in conjunction
with IM/MM-BK1.
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.
1INTRODUCTION

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
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
2.1 Unpacking
2.2 Installation Conditions
2MECHANICAL INSTALLATION

3
IP65
(NEMA 4)
80°C (176°F)
Maximum !
–10°C (14°F)
Minimum
Backfill
Metal
Protection
Plate
Supports
Supports
2MECHANICAL 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.
Caution. Do not overtighten fixings,
especially on an uneven surface.
Fig. 2.16 Dimensions
Fig. 2.17 Gasket Fitting
Caution. For wafer type sensors of
<15mm bore, the fluid seal must be
made against the PTFE. Otherwise use a
full face gasket.
Fig 2.18 Wafer Type Sensors

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)
>4mm2
(<10 AWG)
Copper Wire
Detail of grounding
rings required for
BOTH flanges
>4mm
2
(<10AWG)
Copper Wire
Common Ground
(Plant bonding)
Supplied Bonding Cables
Fig. 3.1 Pipelines
Fig. 3.2 Pipelines with Cathodic Protection
3ELECTRICAL INSTALLATION
3.1 Grounding (Fig. 3.1, 3.2)

6
Filler
Red wire (CD1)
Optional Steel Wire Armor
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
Inches 321
0
0
50
Millimetres
100
150
Overjacket Armor
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
3.2 Cables
3.2.1 Cable (Remote Versions only)
Fig. 3.3 Cable Identification
Fig. 3.4 Cable Preparation

7
Signal Core/Wires
Inner Insulation (Pink)
Conductive Layer (Black)
Screen
Insulation (Grey)
Foil Screen
Signal Core/Wires
Inner Insulation (Blue)
Conductive Layer (Black)
Screen
Insulation (White)
Foil Screen
Red
Violet
Green/Yellow Outer Jacket
Outer Drain Wire
Screen
Yellow
Grey Coaxial Core/Wires White Coaxial Core/Wires
Cable - Part No. STT3350
Red
Yellow
Outer
Insulation Length for
Probe Head
Length for
Transmitter
Grey covered coax
Inner to SIG2. Screen to DS2
Violet 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
3ELECTRICAL INSTALLATION…
3.2.2 Cable (Alternative Type – North American Wiring Practice)
3.2.3 Cable Glands (IEC Installation Practice)
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)

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