ABB ProcessMaster FEP611 User manual

Operating Instruction OI/FEP610/FEH610-EN Rev. B
ProcessMaster FEP610, HygienicMaster FEH610
Electromagnetic flowmeter
Measurement made easy

2 OI/FEP610/FEH610-EN Rev. B | ProcessMaster FEP610, HygienicMaster FEH610
Short product description
Electromagnetic flowmeter can measure the volume flowrate
and the mass flowrate (based on a fixed density to be
programmed).
Devices firmware version: 00.01.04
Further information
A
dditional documentation on ProcessMaster FEP610,
HygienicMaster FEH610 is available for download free of
charge at www.abb.com/flow.
A
lternatively simply scan this code:
Hersteller
A
BB Automation Products GmbH
Measurement & Analytics
Dransfelder Str. 2
37079 Göttingen
Germany
Tel: [phone]
Fax: [phone]
Kundencenter Service
Tel: [phone]
Mail: [email protected]
A
BB Inc.
Measurement & Analytics
125 E. County Line Road
Warminster, PA 18974
USA
Tel: [phone]
Fax: [phone]
A
BB Engineering (Shanghai) Ltd.
Measurement & Analytics
No. 4528, Kangxin Highway, Pudong New
District
Shanghai, 201319,
P.R. China
Tel: [phone]
Fax: [phone]
Mail: [e-mail]

ProcessMaster FEP610, HygienicMaster FEH610 | OI/FEP610/FEH610-EN Rev. B 3
Change from one to two columns
Contents
1Safety............................................................................... 5
1.1General information and instructions .................... 5
1.2Warnings ............................................................. 5
1.3Intended use........................................................ 5
1.4Improper use ....................................................... 5
1.5Warranty provisions ............................................. 5
2Function and System Design.......................................... 6
2.1Overview ............................................................. 6
2.1.1ProcessMaster .................................................... 6
2.1.2HygienicMaster.................................................... 7
2.1.3Transmitter .......................................................... 8
2.2Model variants ..................................................... 9
2.3Measuring principle.............................................. 9
3Product identification.................................................... 10
3.1Name plate........................................................ 10
3.1.1Integral mount design ........................................ 10
4Transport and storage .................................................. 12
4.1Inspection.......................................................... 12
4.2Transport........................................................... 12
4.3Storing the device.............................................. 12
4.4Returning devices .............................................. 12
5Installation ..................................................................... 13
5.1Installation conditions......................................... 13
5.1.1General information............................................ 13
5.1.2Brackets and supports....................................... 13
5.1.3Gaskets............................................................. 13
5.1.4Devices with a wafer-type design....................... 14
5.1.5Flow direction .................................................... 14
5.1.6Elektrode axis .................................................... 14
5.1.7Mounting position .............................................. 14
5.1.8Minimum distance.............................................. 15
5.1.9Inlet and outlet sections ..................................... 15
5.1.10Free inlet or outlet .............................................. 16
5.1.11Strongly contaminated measuring media............ 16
5.1.12Installation in the vicinity of pumps ..................... 16
5.1.13Installation in pipelines with larger nominal
diameters .......................................................... 17
5.1.14Installation in 3A-compliant installations.............. 17
5.2Installing the sensor ........................................... 18
5.3Opening and closing the terminal box ................ 18
5.3.1Rotating the LCD indicator................................. 19
5.4Grounding the flowmeter sensor ........................ 19
5.4.1General information on ground connections ....... 19
5.4.2Metal pipe with fixed flanges .............................. 19
5.4.3Metal pipe with loose flanges ............................. 20
5.4.4Plastic pipes, non-metallic pipes or pipes with
insulating liner .................................................... 20
5.4.5Sensor type HygienicMaster .............................. 20
5.4.6Grounding for devices with protective plates ...... 20
5.4.7Grounding with conductive PTFE grounding plate20
5.4.8Installation and grounding in pipelines with cathodic
corrosion protection........................................... 21
5.5Electrical connections ........................................ 22
5.5.1Connecting the power supply............................. 22
5.5.2Installing the connecting cables.......................... 22
5.5.3Connection using a cable conduit ...................... 23
5.5.4Connection with IP rating IP 68 .......................... 23
5.5.5Electrical connection .......................................... 25
5.5.6Electrical data for inputs and outputs ................. 26
5.5.7Connection to integral mount design.................. 27
5.5.8Connection to remote mount design .................. 28
6Commissioning.............................................................. 31
6.1Safety instructions.............................................. 31
6.2Write-protection switch, service LED and local
operating interface ............................................. 31
6.3Checks prior to commissioning .......................... 32
6.4Parameterization of the device ........................... 32
6.4.1Parameterization via the infrared service port
adapter.............................................................. 33
6.4.2Parameterization via the local operating interface 33
6.5Factory settings ................................................. 34
6.6Switching on the power supply .......................... 34
6.7Parameterization via the "Easy Setup" menu
function ............................................................. 34
6.8Measuring range table ....................................... 37
7Operation....................................................................... 38
7.1Safety instructions.............................................. 38
7.2Menu navigation ................................................ 38
7.3Menu levels........................................................ 39
7.3.1Process display.................................................. 40
7.3.2Switching to the information level (operator menu)40
7.3.3Error messages on the LCD display ................... 41
7.3.4Switching to the configuration level
(parameterization) .............................................. 41
7.3.5Selecting and changing parameters ................... 42
7.4Parameter overview ........................................... 44
7.5Parameter descriptions ...................................... 49
7.5.1Available units.................................................... 49
7.5.2Menu: Easy Setup.............................................. 50
7.5.3Menu: Device Info .............................................. 51
7.5.4Menu: Device Setup........................................... 53
7.5.5Menu: Display.................................................... 56
7.5.6Menu: Input/Output ........................................... 57
7.5.7Menu: Process Alarm......................................... 60
7.5.8Menu: Diagnostics ............................................. 61
7.5.9Menu: Totalizer .................................................. 63
7.6Software history................................................. 63

4 OI/FEP610/FEH610-EN Rev. B | ProcessMaster FEP610, HygienicMaster FEH610
8Diagnosis / error messages.......................................... 64
8.1Calling up the error description .......................... 64
8.2Error messages ................................................. 65
8.2.1Errors ................................................................ 65
8.2.2Function check .................................................. 66
8.2.3Operation outside of specifications (Out Of Spec.)66
8.2.4Maintenance...................................................... 67
8.3Overview ........................................................... 68
9Maintenance.................................................................. 71
9.1Safety instructions ............................................. 71
9.2Flowmeter sensor .............................................. 71
9.2.1Gaskets............................................................. 71
9.3Cleaning ............................................................ 71
10Repair ............................................................................ 72
10.1Spare parts........................................................ 72
10.2Fuse replacement .............................................. 72
10.3Replacing the LCD indicator .............................. 73
10.4Replacing the transmitter ................................... 74
10.5Replacing the flowmeter sensor ......................... 75
10.6Loading the system data.................................... 76
10.7Returning devices .............................................. 76
11Recycling and disposal................................................. 77
11.1Dismounting ...................................................... 77
11.2Disposal ............................................................ 77
11.3Information on ROHS Directive 2011/65/EC....... 77
12Specifications................................................................ 78
12.1Permitted pipe vibration ..................................... 78
12.2ProcessMaster - Temperature data.................... 78
12.2.1Maximum permissible cleaning temperature....... 78
12.2.2Ambient temperature as a function of measuring
medium temperature ......................................... 79
12.3ProcessMaster - Material loads for process
connections....................................................... 80
12.4HygienicMaster - Temperature data ................... 83
12.4.1Maximum permissible cleaning temperature....... 83
12.4.2Ambient temperature as a function of measuring
medium temperature ......................................... 83
12.5HygienicMaster - Material loads for process
connections....................................................... 84
13Appendix ....................................................................... 86
13.1Return form ....................................................... 86
13.2Declarations of conformity.................................. 86
13.3Torque information............................................. 87
13.3.1Torque information for sensors designLevel A .... 87
13.3.2Torque information for sensors Design Level B... 91
13.4Overview parameter settings (factory default
settings)............................................................. 93

ProcessMaster FEP610, HygienicMaster FEH610 | OI/FEP610/FEH610-EN Rev. B 5
1Safety
Change from one to two columns
1.1 General information and instructions
These instructions are an important part of the product and
must be retained for future reference.
Installation, commissioning, and maintenance of the product
may only be performed by trained specialist personnel who
have been authorized by the plant operator accordingly. The
specialist personnel must have read and understood the
manual and must comply with its instructions.
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 nor an
amendment to any previous or existing agreement, promise or
legal relationship.
Modifications and repairs to the product may only be
performed if expressly permitted by these instructions.
Information and symbols on the product must be observed.
These may not be removed and must be fully legible at all
times.
The operating company must strictly observe the applicable
national regulations relating to the installation, function testing,
repair and maintenance of electrical products.
1.2 Warnings
The warnings in these instructions are structured as follows:
DANGER
The signal word "DANGER" indicates an imminent danger.
Failure to observe this information will result in death or
severe injury.
WARNING
The signal word "WARNING" indicates an imminent danger.
Failure to observe this information may result in death or
severe injury.
CAUTION
The signal word "CAUTION" indicates an imminent danger.
Failure to observe this information may result in minor or
moderate injury.
NOTE
The signal word "NOTE" indicates useful or important
information about the product.
The signal word "NOTE" is not a signal word indicating a
danger to personnel. The signal word "NOTE" can also refer
to material damage.
1.3 Intended use
This device is intended for the following uses:
— To transmit fluid, pulpy or pasty measurement media with
electrical conductivity.
— For volume flow measurement (under operating
conditions).
— For mass flow measurement (based on a fixed density to
be programmed).
The device has been designed for use exclusively within the
technical limit values indicated on the identification plate and
in the data sheets.
In terms of the measuring medium, observe following points:
— Wetted parts such as measuring electrodes, liner,
grounding electrodes, grounding rings, protection flanges
must not be damaged because of the chemical and
physical characteristic of the measuring medium.
— Media with unknown properties or abrasive measuring
media may only be used if regular and suitable tests can
be performed to ensure the safe condition of the device.
— The information on the name plate must be observed.
— Prior to using corrosive and abrasive measurement media,
the operator must check the level of resistance of all parts
coming into contact with the measuring medium.
ABB will gladly support you in selecting the materials, but
cannot accept any liability in doing so.
1.4 Improper use
The following are considered to be instances of improper use
of the device:
— For operating as a flexible adapter in piping, e.g. for
compensating pipe offsets, pipe vibrations, pipe
expansions, etc.
— For use as a climbing aid, e.g. for mounting purposes
— For use as a support for external loads, e.g. as a support
for piping, etc.
— Material application, e.g. by painting over the name plate
or welding/soldering on parts
— Material removal, e.g. by spot drilling the housing
1.5 Warranty provisions
Using the device in a manner that does not fall within the
scope of its intended use, disregarding this manual, 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.
Change from tw o to one column

6 OI/FEP610/FEH610-EN Rev. B | ProcessMaster FEP610, HygienicMaster FEH610
2Function and System Design
2.1 Overview
2.1.1 ProcessMaster
Integral mount design Remote mount design
Fig. 1: Designs
1Flowmeter sensor, Design Level A (DN 3 … 2000) 2Flowmeter sensor, Design Level B (DN 25 … 600) 3Remote transmitter
Flowmeter sensor
Model ProcessMaster FEP611, FEP612
Housing Integral mount design, remote mount design
Measuring accuracy for liquids 0.5 % of measured value
Permissible measuring medium
temperature Tmedium
-25 ... 130 °C (-13 ... 266 °F)
Minimum conductivity > 20 µS/cm (20 µS/cm for demineralized water)
Nominal pressure rating PN 10 … 40; ASME CL 150, 300; JIS 10K
Nominal diameter DN 3 ... 2000 (1/10 “ ... 80 “)
Process connection Flange1) according to DIN, ASME, JIS
Process connection material Steel, cast iron, stainless steel
Liner material Hard rubber (DN 15 ... 2000), soft rubber (DN 50 ... 2000), PTFE (DN 10 ... 600), PFA (DN 3 ... 200),
ETFE (DN 25 ... 600)
Electrode material Stainless steel, Hastelloy B, Hastelloy C, platinum-iridium, tantalum, titanium
IP rating Integral mount design: IP 65 / IP 67
Remote mount design: IP 65 / IP 67 / IP 68 (sensor only)
Approvals
Pressure Equipment Directive
2014/68/EU
Conformity assessment in accordance with category III, fluid group 1
CRN (Canadian Reg.Number) On request
Further approvals At www.abb.com/flow or on request.
1) For information on flange thicknesses, see the chapter "Dimensions" in the Datasheet.
G12001
12 312
FEP611 FEP611 FEP612 FEP612 FET612

ProcessMaster FEP610, HygienicMaster FEH610 | OI/FEP610/FEH610-EN Rev. B 7
2.1.2 HygienicMaster
Integral mount design Remote mount design
Fig. 2: Designs
1Flowmeter sensor 2Remote transmitter
Flowmeter sensor
Model HygienicMaster FEH611, FEH612
Housing Integral mount design, remote mount design
Measuring accuracy for liquids 0.5 % of measured value
Permissible measuring medium
temperature Tmedium
-25 ... 130 °C (-13 ... 266 °F)
Minimum conductivity > 20 µS/cm (20 µS/cm for demineralized water)
Nominal pressure PN 10 … 40, ASME CL 150, 300, JIS 10K
Nominal diameter DN 3 ... 100 (1/10 “ ... 4 “)
Process connection Wafer type design:
Flange in acc. with DIN, ASME or JIS:
Threaded pipe connection in acc. with DIN 118511):
Weld stubs1):
Tri-Clamp in acc. with DIN 326761):
Tri-Clamp in acc. with ASME BPE1):
External thread in acc. with ISO 228 / DIN 2999:
DN 3 ... 100 (1/10 ... 4“)
DN 3 ... 100 (1/10 ... 4“), PN 10 ... 40
DN 3 ... 100 (1/10 ... 4“), PN 10 ... 40
DN 3 ... 100 (1/10 ... 4“), PN 10 ... 40
DN 3 ... 100 (1/10 ... 4“), PN 10 ... 16
DN 3 ... 100 (1/10 ... 4“), PN 10
DN 3 ... 25 (1/10 ... 1“), PN 16
Process connection material Stainless steel
Liner material PFA (vakuum tight)
Electrode material CrNi steel 1.4571 (AISI 316Ti), 1.4539 [904L], Hastelloy B, Hastelloy C, platinum-iridium, tantalum, titanium
IP rating Integral mount design: IP 65 / IP 67
Remote mount design: IP 65 / IP 67 / IP 68 (sensor only)
Approvals
Pressure Equipment Directive
2014/68/EU
Conformity assessment in accordance with category III, fluid group 1
CRN (Canadian Reg.Number) On request
Hygienic design approvals 3A, FDA-approved materials
Further approvals At www.abb.com/flow or on request.
1) 3A approved
G12002
2
11
FEH611 FEH612 FET612

8 OI/FEP610/FEH610-EN Rev. B | ProcessMaster FEP610, HygienicMaster FEH610
2.1.3 Transmitter
Transmitter
Model FET612
Housing Integral mount design (see Fig. 2), remote mount design.
IP rating IP 65 / IP 67
Cable length Maximum 50 m (164 ft), remote mount design only
Power supply 100 ... 240 V AC (-15 / +10 %),
24 ... 48 V DC (-10% / +10 %)
Outputs Current output: 4 … 20 mA, active
Digital output 1: passive, configurable as pulse, frequency or switch output
Digital output 2: passive, configurable as pulse or switch output
Local display Configurable graphical display (option)
Approvals
— Further approvals At www.abb.com/flow or on request.
Change from one to two columns

ProcessMaster FEP610, HygienicMaster FEH610 | OI/FEP610/FEH610-EN Rev. B 9
2.2 Model variants
Integral mount design
For devices with an integral mount design, the transmitter and
the flowmeter sensor form a single mechanical unit
Remote mount design
For devices with a remote mount design, the transmitter and
flowmeter sensor are mounted in separate locations.
The electrical connection between the transmitter and the
flowmeter sensor is provided by a signal cable.
When the minimum conductivity of the measuring medium is
20 S/cm, a maximum signal cable length of 50 m (164 ft) is
possible.
Notes on ProcessMaster
The ProcessMaster flowmeter sensor is available in two
models, which are distinguished by the design level (A / B).
2.3 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.
Fig. 3: Electromagnetic flowmeter schematic
1Magnet coil 2Measuring tube in electrode plane 3Signal
electrode
vDBU ~
1
v
D
qv 

4
2

qvU ~
1
U1Signal voltage
B Magnetic induction
D Electrode spacing
v Average flow velocity
qvVolume flow
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 Fig. 3).
The voltage induced in the fluid is measured by two electrodes
located diametrically opposite each other. This signal voltage
is proportional to the magnetic induction, the electrode
spacing and the average flow velocity.
Considering that the magnetic induction and the electrode
spacing are constant values, a proportionality exists between
the signal voltage UE and the average flow velocity.
From the equation for calculating the volume flowrate, it
follows that the signal voltage is linearly proportional to the
volume flowrate.
The induced voltage is converted by the transmitter to
standardized, analog and digital signals.
G12000
U₁
y
z
x
v
B
D
E
1
2
2

10 OI/FEP610/FEH610-EN Rev. B | ProcessMaster FEP610, HygienicMaster FEH610
3Product identification
3.1 Name plate
3.1.1 Integral mount design
Fig. 4: Name plate integral mount design (example)
1Type designation 2CE mark 3Nominal diameter / Process
connection / pressure rating 4Flange material 5Medium
temperature range 6Ambient temperature range 7Calibration
value QmaxDN 8"Follow operating instructions" symbol 9"Hot
surface" symbol jPED marking kPower supply lIP rating
mYear of manufacture (month / year) nManufacturer oOrder
code pSerial number qTAG number rDevice Firmware
version sSensor calibration data tExcitation frequency
Remote mount design
Fig. 5: Name plate remote mount design (example)
AFlowmeter sensor BTransmitter
1Type designation 2CE mark
3Nominal diameter / Process connection / pressure rating
4Meter tube material 5Medium temperature range
6Ambient temperature range 7Calibration value QmaxDN
8"Follow operating instructions" symbol 9"Hot surface" symbol
jPED marking kIP rating lYear of manufacture (month / year)
mManufacturer nOrder code oSerial number pPower
supply qMaximum voltage at inputs and outputs rTAG number
sSensor calibration data tExcitation frequency uDevice
Firmware version
G12003
s
t
r
q
q
1 2
3
4
5
6
7
89m
n
o
p
jkl
G12004
1 2
3
4
5
6
7
89
l
m
n
o
j
8
1 2
A
B
lm
o
n
q
p
k6
k
s
t
u
r
r

ProcessMaster FEP610, HygienicMaster FEH610 | OI/FEP610/FEH610-EN Rev. B 11
The marking according to the Pressure Equipment Directive
(PED) can be found on the name plate.
Fig. 6: PED marking (example)
1CE mark (with number of labeled location) 2Nominal size /
nominal pressure rating 3Material (wetted parts) 4Fluid group
resp. reason for the exception 5Serial number of the flowmeter
sensor
The marking is applied depending to the nominal size
(> DN 25 or ≤ DN 25) of the flowmeter (also refer to Pressure
Equipment Directive 97/23/EC).
Pressure equipment subject to PED
Below the CE mark, the number of the designated authority to
confirm that the device meets the requirements of Pressure
Equipment Directive is specified.
The respective fluid group in accordance with the Pressure
Equipment Directive is indicated under PED.
Example: Fluid group 1 = hazardous fluids, gaseous.
Pressure equipment outside the applicable range of the
PED
Under PED, the reason for the exception in article 3,
paragraph 3 of the Pressure Equipment Directive is specified.
The pressure equipment is classified in the SEP (= Sound
Engineering Practice) "Good Engineering Practice" category.
G12005
1
4
52
3

12 OI/FEP610/FEH610-EN Rev. B | ProcessMaster FEP610, HygienicMaster FEH610
4Transport and storage
4.1 Inspection
Check the devices immediately after unpacking for possible
damage that may have occurred from improper transport.
Details of any damage that has occurred in transit must be
recorded on the transport documents.
All claims for damages must be submitted to the shipper
without delay and before installation.
4.2 Transport
DANGER
Life-threatening danger due to suspended loads.
In the case of suspended loads, a danger of the load falling
exists.
Remaining under suspended loads is prohibited.
WARNING
Risk of injury due to device slipping.
The device's center of gravity may be higher than the
harness suspension points.
— Make sure that the device does not slip or turn during
transport.
— Support the device laterally during transport.
NOTE
Potential damage to device!
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
Fig. 7: Transport instructions - ≤ DN 450
Flange devices ≤ DN 450
— Carrying straps must be used to transport flange designs
smaller than DN 450
— Wrap the straps around both process connections when
lifting the device
— Chains should not be used, since these may damage the
housing.
Flange devices > DN 450
Fig. 8: Transport instructions - > DN 450
— Using a forklift to transport flange device can bend the
housing.
— Flange devices must not be lifted by the center of the
housing when using a forklift for transport.
— Flange devices must not be lifted by the terminal box or by
the center of the housing.
— Only the transport lugs fitted to the device can be used to
lift the device and insert it into the piping.
4.3 Storing the device
Bear the following points in mind when storing devices:
— Store the device in its original packaging in a dry and
dust-free location.
— Observe the permitted ambient conditions for transport
and storage.
— Avoid storing the device in direct sunlight.
— In principle, the devices may be stored for an unlimited
period. However, the warranty conditions stipulated in the
order confirmation of the supplier apply.
Storage temperature range
-30 ... 70 °C (-22 ... 158 °F)
The ambient conditions for the transport and storage of the
device correspond to the ambient conditions for operation of
the device.
Adhere to the device data sheet!
4.4 Returning devices
For the return of devices, follow the instructions in the chapter
"Returning devices" on page 76.
G12034
G10645

ProcessMaster FEP610, HygienicMaster FEH610 | OI/FEP610/FEH610-EN Rev. B 13
5Installation
5.1 Installation conditions
5.1.1 General information
The following points must be observed during installation:
— The flow direction must correspond to the marking, if
present.
— The maximum torque for all flange screws must be
complied with.
— Secure the flange bolts and nuts against pipe vibration.
— The devices must be installed without mechanical tension
(torsion, bending).
— Install flange devices / wafer-type devices with plane
parallel counterflanges and use appropriate gaskets only.
— Only gaskets made from a material that is compatible with
the measuring medium and measuring medium
temperature may be used.
— Gaskets must not extend into the flow area, since possible
turbulence could influence the accuracy of the device.
— The piping may not exert any inadmissible forces or
torques on the device.
— Make sure temperature limits are not exceeded operating
the device.
— Vacuum shocks in the piping should be avoided to prevent
damage to the liners (PTFE). Vacuum shocks can destroy
the device.
— Do not remove the sealing plugs in the cable glands until
you are ready to install the electrical cable.
— Make sure the gaskets for the housing cover are seated
correctly. Carefully gasket the cover. Tighten the cover
fittings.
— The transmitter with a remote mount design must be
installed at a largely vibration-free location.
— Do not expose the transmitter and sensor to direct
sunlight. Provide appropriate sun protection as necessary.
— When installing the transmitter in a control cabinet, make
sure adequate cooling is provided.
— In case of a remote mounted transmitter make sure that
the sensor and the transmitter have been assigned
correctly. Compatible devices have the same end
numbers on the name plate, e.g. flowmeter sensor X001
belongs to transmitter Y001 or flowmeter sensor X002
belongs to transmitter Y002.
5.1.2 Brackets and supports
NOTE
Potential damage to device!
Improper support for the device may result in deformed
housing and damage to internal magnet coils.
Place the supports at the edge of the flowmeter sensor
housing (see arrows in Fig. 9).
Fig. 9: Support for meter sizes larger than DN 400
Devices with meter sizes larger than DN 400 must be mounted
with support on a sufficiently strong foundation.
5.1.3 Gaskets
The following points must be observed when installing
gaskets:
— For achieve the best results, ensure the gaskets fit
concentrically with the meter tube
— To ensure that the flow profile is not distorted, the gaskets
must not protrude into the piping.
— The use of graphite with the flange or process connection
gaskets is prohibited, because an electrically conductive
coating may form on the inside of the meter tube.
Devices with a hard rubber, soft rubber liner
— Devices with a hard / soft rubber liner always require
additional gaskets.
— ABB recommends using gaskets made from rubber or
rubber-like sealing materials.
— When selecting the gaskets, ensure that the tightening
torques specified in chapter "Torque information" on
page 87 are not exceeded.
Devices with a PTFE, PFA or ETFE liner
— In principle, devices with a PTFE, PFA or ETFE liner do not
require additional gaskets.
G10649

14 OI/FEP610/FEH610-EN Rev. B | ProcessMaster FEP610, HygienicMaster FEH610
5.1.4 Devices with a wafer-type design
Fig. 10: Installation set for wafer-type installation (example)
1Threaded rod 2Nut with washer 3Centering sleeves
For devices with a wafer-type design, ABB offers an
installation set as an accessory that comprises threaded rods,
nuts, washers and centering sleeves for installation.
5.1.5 Flow direction
Fig. 11: Flow direction
The device measures the flowrate in both directions. Forward
flow is the factory setting, as shown in Fig. 11.
5.1.6 Elektrode axis
Fig. 12: Orientation of the electrode axis
1Elektrode axis
The electrode axis should be horizontal if at all possible or no
more than 45° from horizontal.
5.1.7 Mounting position
Fig. 13: Mounting position
AVertical installation for measuring abrasive fluids,
preferably with flow in upward direction.
BIn case of horizontal installation, the Meter tube must
always be completely full.
Provide for a slight incline of the connection for degassing.
NOTE
Prefer vertical installation in hygienic applications!
With horizontal installation assure the sensor is self-
drainable.
G12060
1 2 3 3
G12006
G12007
≤ 45°
1
G12009
AB
3°

ProcessMaster FEP610, HygienicMaster FEH610 | OI/FEP610/FEH610-EN Rev. B 15
5.1.8 Minimum distance
Distance D: ≥ 1.0 m (3.3 ft ) for design level "A", ≥ 0.7 m (2.3 ft) for
design level "B"
Distance D: ≥ 1.0 m (≥ 3.3 ft )
Fig. 14: Minimum distance
— In order to prevent the devices from interfering with each
other, a minimum distance as shown in Fig. 14 must be
maintained between the devices.
— 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.
5.1.9 Inlet and outlet sections
Fig. 15: In- and outlet section, turn-off component
1Double elbow 2Turn-off component
The metering principle is independent of the flow profile as
long as standing eddies do not extend into the metering
section, such as may occur after double elbows, in the event
of tangential inflow, or where half-open gate valves are located
upstream of the flowmeter sensor.
In such cases, measures must be put in place to normalize the
flow profile.
ADo not install fittings, manifolds, valves, etc., directly in
front of the flowmeter sensor.
BInlet and outlet section: Length of straight inlet and outlet
section of the flowmeter sensor.
Experience has shown that, in most installations, inlet
sections 3 x DN long and outlet sections 2 x DN long are
sufficient (DN = nominal diameter of the flowmeter sensor).
For test stands, the reference conditions of 10 x DN inlet
section and 5 x DN outlet section must be provided, in
accordance with EN 29104 / ISO 9104.
Valves or other turn-off components should be installed in
the outlet section.
Butterfly valves must be installed so that the valve plate
does not extend into the flowmeter sensor.
G12013
ProcessMaster FEPxxx
D
G12063
HygienicMaster FEHxxx
D
G12008
3 x DN 2 x DN
A
B
1
2
2

16 OI/FEP610/FEH610-EN Rev. B | ProcessMaster FEP610, HygienicMaster FEH610
5.1.10 Free inlet or outlet
Fig. 16: Free inlet or outlet
ADo not install the flowmeter at the highest point or in the
draining off side of the pipeline, flowmeter runs empty, air
bubbles can form.
BProvide for a siphon fluid intake for free inlets or outlets so
that the pipeline is always ful.
5.1.11 Strongly contaminated measuring media
Fig. 17: Bypass connection
For strongly contaminated measuring media, a bypass
connection according to the figure is recommended so that
operation of the system can continue to run without
interruption during the mechanical cleaning.
5.1.12 Installation in the vicinity of pumps
Fig. 18: Vibration damping
1Pump 2Damping device 3Shut-off device
Strong vibrations in the pipeline must be damped using flexible
damping devices.
The damping devices must be installed beyond the supported
flowmeter section and outside of the section between the
shut-off devices.
Do not connect flexible damping devices directly to the
flowmeter sensor.
G12010
AB
G12011
G12012
1 2 3

ProcessMaster FEP610, HygienicMaster FEH610 | OI/FEP610/FEH610-EN Rev. B 17
5.1.13 Installation in pipelines with larger nominal
diameters
Fig. 19: using reduction pieces
1Transition piece
Determine the resulting pressure loss when using transition
pieces:
1. Calculate the diameter ratio d/D.
2. Determine the flow velocity based on the flow range
nomograph (Fig. 20).
3. Read the pressure drop on the Y-axis in Fig. 20.
Fig. 20: Nomograph for pressure drop calculations for flange
transition piece with α/2 = 8°
5.1.14 Installation in 3A-compliant installations
Fig. 21: 3A-compliant installation
1Mounting bracket 2Leakage hole
Please observe the following points:
ADo not install the device horizontally with the terminal box
or transmitter housing pointing downward.
BThe "mounting bracket" option is not 3A-compliant.
CPlease ensure that the leakage hole of the process
connection is located at the deepest point of the installed
device.
— Prefer vertical installation. With horizontal installation make
sure the sensor is self-drainable
— Make sure the sensor terminal compartment cover and/or
the transmitter housing cover is tightened properly to
ensure there is no gap between the base of the housing
and the cover.
Only devices with following process connections are 3A-
compliant:
— Welded stubs
— Tri-Clamp
G12014
D
d
8°
1
G12015
100
10
1
v=8 m/s
7 m/s
6 m/s
5 m/s
4 m/s
3 m/s
2 m/s
1 m/s
d/D
[mbar]
0,5 0,6 0,7 0,8 0,9
G12016
1 2
AB C

18 OI/FEP610/FEH610-EN Rev. B | ProcessMaster FEP610, HygienicMaster FEH610
5.2 Installing the sensor
NOTE
Potential damage to device!
— The use of graphite with the flange or process
connection gaskets is prohibited. This is because, in
some instances, an electrically conductive coating may
form on the inside of the meter tube.
— Vacuum shocks in the piping should be avoided to
prevent damage to the liners (PTFE). Vacuum shocks
can destroy the device.
The flowmeter sensor can be installed at any location in the
piping while taking the installation conditions into account.
1.Remove protective plates, if present, to the right and left
of the meter tube. To prevent possible leakage, make sure
that the liner on the flange is not cut or damaged.
2.Position the flowmeter sensor coplanar and centered
between the piping.
3.Install gaskets between the surfaces; see chapter
"Gaskets" on page 13.
NOTE
For achieve the best results, ensure the gaskets fit
concentrically with the meter tube
To ensure that the flow profile is not distorted, the gaskets
must not protrude into the piping.
4.Use the appropriate screws for the holes in accordance
with chapter "Torque information" on page 87.
5.Slightly grease the threaded nuts.
6.Tighten the nuts in a crosswise manner as shown in the
figure. Observe the tightening torques in accordance with
chapter "Torque information" on page 87!
First tighten the nuts to approx. 50 % of the maximum
torque, then to 80 %, and finally a third time to the
maximum torque. Do not exceed the maximum torque.
Fig. 22: Tightening sequence for the flange screws
5.3 Opening and closing the terminal box
WARNING
Risk of injury due to live parts!
When the housing is open, contact protection is not provided
and EMC protection is limited.
Before opening the housing, switch off the power supply.
NOTE
Impairment of the IP rating
— Make sure that the cover of the power supply terminals
is mounted correctly.
— Check the O-ring gasket for damage and replace it if
necessary before closing the housing cover.
— Check that the O-ring gasket is properly seated when
closing the housing cover.
Fig. 23: Cover safety device (example)
To open the housing, release the cover safety device by
screwing in the screw 1.
After closing the housing, lock the housing cover by
unscrewing the screw 1.
G11726
1
2
7
8
5
3
4
6
1
2
3
4
G12061
1

ProcessMaster FEP610, HygienicMaster FEH610 | OI/FEP610/FEH610-EN Rev. B 19
5.3.1 Rotating the LCD indicator
Depending on the installation position, the LCD display can be
rotated in 4 increments of 90° to enable horizontal readings.
Refer to chapter "Opening and closing the terminal box" on
page 18!
Rotating the LCD display: Perform steps A… G.
Fig. 24: Rotating the LCD display (example)
5.4 Grounding the flowmeter sensor
5.4.1 General information on ground connections
Observe the following items when grounding the device:
—For plastic pipes or pipes with insulating lining, the earth is
provided by the grounding ring or grounding electrodes.
—When stray potentials are present, install a grounding ring
upstream and downstream of the flowmeter sensor.
—For measurement-related reasons, the potentials in the
station ground and in the pipeline should be identical.
NOTE
If the flowmeter sensor is installed in plastic or earthenware
pipelines, or in pipelines with an insulating lining, transient
current may flow through the grounding electrode in special
cases.
In the long term, this may destroy the sensor, since the
grounding electrode will in turn degrade electrochemically. In
these special cases, the connection to the earth must be
performed using grounding rings. Install a grounding ring
upstream and downstream of the device in this case.
5.4.2 Metal pipe with fixed flanges
Fig. 25: Metal pipe, without liner (example)
AFlange design BWafer-type design
1Ground terminal
Use a copper wire (at least 2.5 mm² (14 AWG)) to establish the
ground connection between the sensor, the pipeline flanges
and an appropriate grounding point.
G12062
A
E
B
C
DF
G
G12021
1
1
AB

20 OI/FEP610/FEH610-EN Rev. B | ProcessMaster FEP610, HygienicMaster FEH610
5.4.3 Metal pipe with loose flanges
Fig. 26: Metal pipe, without liner (example)
AFlange design BWafer-type design
1Threaded nuts M6 2Ground terminal
1.Solder the threaded nuts M6 to the pipeline and connect
the ground as shown in the illustration.
2.Use a copper wire (at least 2.5 mm2(14 AWG)) to
establish the ground connection between the sensor and
an appropriate grounding point.
5.4.4 Plastic pipes, non-metallic pipes or pipes with
insulating liner
Fig. 27: Plastic pipes, non-metallic pipes or pipes with insulating
liner
AFlange design BWafer-type design
1Earth connection 2Terminal lug 3Grounding ring
For plastic pipes or pipes with insulating lining, the grounding
for the measuring medium is provided by the grounding ring
as shown in the figure below or via grounding electrodes that
must be installed in the device (option). If grounding electrodes
are used, the grounding ring is not necessary.
1.Install the flowmeter sensor with grounding ring in the
pipeline.
2.Connect the terminal lug for the grounding ring and
ground connection on the flowmeter sensor with the
grounding strap.
3.Use a copper wire (min. 2.5 mm² (14 AWG)) to link the
ground connection to a suitable grounding point.
5.4.5 Sensor type HygienicMaster
Fig. 28
1Process connection adapter
Ground the stainless steel model as shown in the figure. The
measuring fluid is grounded via the process connection
adapter and an additional ground is not required.
5.4.6 Grounding for devices with protective plates
The protective plates are used to protect the edges of the liner
in the meter tube, e.g., for abrasive fluids. In addition, they
function as a grounding ring.
— For plastic or pipes with insulating lining, electrically
connect the protective plate in the same manner as a
grounding ring.
5.4.7 Grounding with conductive PTFE grounding plate
For devices with a meter size between DN 10 … 250,
grounding rings made of conductive PTFE are available. These
are installed in a similar way to conventional grounding ring.
G12022
1
1
2
2
AB
G12023
2
1
1
3
AB
3
2
G12024
1