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ABB AquaMaster 3, User Manual

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User Guide OI/FET2XX–EN Rev. E

AquaMaster 3

Electromagnetic flowmeter

The smart solution for 
remote applications

Introduction

AquaMaster 3

TM

 is a range of high performance 

electromagnetic flowmeters for the measurement of 
electrically-conductive fluids and is normally supplied as 
factory-configured, calibrated systems.

This User Guide provides end-user details for 
AquaMaster 3 close-coupled and remote transmitters. 

When the meter is taken out of storage and installed for 
first use, remove the protective label (if fitted) from the 
front to enable light to activate the unit. 

If the meter is not powered, connect any batteries or 
external supply as detailed in this manual.

This User Guide should be used in conjunction with the 
following publications:

–

Programming Guide (COI/FET2XX–EN)

–

MODBUS Tables Supplement 
(COI/FET2XX/MOD/TBL–EN)

Summary of Contents for AquaMaster 3

Page 1: ...ystems This User Guide provides end user details for AquaMaster 3 close coupled and remote transmitters When the meter is taken out of storage and installed for first use remove the protective label if fitted from the front to enable light to activate the unit If the meter is not powered connect any batteries or external supply as detailed in this manual This User Guide should be used in conjuncti...

Page 2: ... 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 Quality Control The UKAS Calibration Laboratory No 0255 is just one of the ten flow c...

Page 3: ... 2 Connections 18 3 2 1 AquaMaster 3 Connections 18 3 2 2 Use of Tamper detection Seals 19 3 3 Input Output Connections 20 3 3 1 Frequency Outputs 20 3 3 2 Alarm Interface 21 3 3 3 Input Output Connections 21 3 3 4 ScanReader Interface Option 22 3 3 5 RS232 Local Computer Connection 22 3 3 6 Pressure Transducer Optional 23 3 3 7 Anti tamper Protection 24 3 4 MODBUS Connection 25 3 4 1 2 wire Conne...

Page 4: ...and Sockets 33 4 4 1 Service Intervals 33 4 4 2 Equipment Required 34 4 4 3 Preparation 34 4 4 4 Disconnection 34 4 4 5 Order of Treatment 35 4 4 6 Stage 1 Oxide Removal and Cleaning 35 4 4 7 Stage 2 Oxide Prevention 36 4 4 8 Completion Tasks 36 4 5 Accessories Spares Kits 37 5 Specification 38 Appendix A Hazardous Area Protection 51 A 1 GSM Equipped Units Safety Precautions 51 Notes 52 ...

Page 5: ...61010 1 2010 Safety Requirements for Electrical Equipment for Measurement Control and Laboratory Use and complies with US NEC 500 and Occupational Safety Health Administration If the equipment is used in a manner NOT specified by the Company the protection provided by the equipment may be impaired 1 2 Symbols One or more of the following symbols may appear on the equipment labelling Warning Refer ...

Page 6: ...mal safe handling procedures must be used 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 contact details on the back cover together with servicing and spares information Warning Installation and maintenance must be carri...

Page 7: ...er 2 Mechanical Installation User Guide OI FET2XX EN Rev E 5 2 Mechanical Installation 2 1 Unpacking 2 2 Installation Conditions Fig 2 1 Unpacking Caution Do NOT exceed the maximum working pressure marked on the equipment Fig 2 2 Spillage ...

Page 8: ...quaMaster 3 Electromagnetic flowmeter 2 Mechanical Installation 6 User Guide OI FET2XX EN Rev E Fig 2 3 Vibration Fig 2 4 Localized Heat Fig 2 5 Siting Close coupled Version Allow room to read data plate ...

Page 9: ... 6 Within Temperature Limits Fig 2 7 Straight Pipe Requirements Fig 2 8 Fluid Level 60 C 140 F Maximum 20 C 4 F Minimum 10 C 14 F Minimum 70 C 158 F Maximum 0 Pipe Diameters 0 Pipe Diameters Minimum Minimum Flow Direction 2 Pipe Diameters 5 Pipe Diameters Full Bore Sensor MM GF Reduced Bore Sensor MM GA ...

Page 10: ... OI FET2XX EN Rev E Fig 2 9 Shade Fig 2 10 Within Environmental Rating Fig 2 11 Above Ground Fig 2 12 Temperature Difference 2 m 78 in Submerged 9 Months Accrued Time IP68 NEMA 6P ENCLOSURE 6P Not applicable to GSM Integral Aerial Installations see section 2 4 1 page 13 Supports ...

Page 11: ...r Guide OI FET2XX EN Rev E 9 Fig 2 13 Underground Note For further details when burying flow sensors contact the ABB Service Organisation Fig 2 14 Cable Routing Fig 2 15 Gasket Fitting Adequate Protection Plate Recommended Backfill Fit Gaskets Gaskets same size as pipe ...

Page 12: ...lation 10 User Guide OI FET2XX EN Rev E Fig 2 16 Access to Transmitter Fig 2 17 Separation of Sensors Fig 2 18 Pressure Transducer Protect from Frost For access to display and communication connector 0 7 m 2 3 ft Minimum Pressure Transducer Pressure Transducer ...

Page 13: ...aMaster 3 Dimensions in mm in Fig 2 19 AquaMaster 3 Dimensions Dimensions in mm in Fig 2 20 AquaMaster 3 Battery Pack Dimensions Ø 6 5 0 25 Ø13 0 50 115 4 50 177 7 0 50 2 0 185 7 3 28 1 1 136 5 4 Remote mounted Transmitter Sensor mounted Transmitter 105 4 1 280 11 0 with Connectors 125 5 0 135 5 30 70 2 75 135 5 30 8 0 30 ...

Page 14: ...3 Electromagnetic flowmeter 2 Mechanical Installation 12 User Guide OI FET2XX EN Rev E 2 3 2 Terminal Box Sensor mounted Dimensions in mm in Fig 2 21 Round Terminal Box Dimensions 100 3 93 36 5 1 43 62 2 44 80 3 2 ...

Page 15: ...tor bars are recommended For SMS text a minimum of 1 visible signal strength indicator bar is recommended The following must also be observed when deciding on the antenna mounting location For best results mount the antenna as high above local ground level as possible If the antenna must be mounted below ground achieve optimum results by ensuring there is a strong mobile phone network signal at gr...

Page 16: ...nnecting a Remote Antenna Referring to Fig 2 24 1 Remove the cover A from the socket on top of the transmitter 2 Gently push the antenna plug B into the socket then twist the screw ring clockwise until locked Fig 2 23 GSM Antenna Installation Fig 2 24 Connecting a Remote Antenna 50 mm 2 0 in A B AquaMaster ...

Page 17: ...mitter unscrew and remove the cover A protecting the SIM card holder B 4 If a SIM card is being changed ensure the GSM Engine is off before removing the card by reading 368 see COI FET2XX EN and the status reported in Off 5 Carefully lift the right hand edge of the holder B outwards 6 Slide the SIM card C into the carrier contact side down and bevelled edge to the top right 7 Close the holder B un...

Page 18: ...grounded correctly according to regulations Note Connect the transmitter ground connection to the flowmeter body ground see Fig 3 2 and Fig 3 3 The flow sensor must not be connected to a ground spike For bonding connections use 4 mm2 10AWG cable Older sensors from DN40 to DN80 fitted with bare metal stainless steel flanges do not require fluid contact rings Fig 3 1 Grounding All Pipes Fluid Contac...

Page 19: ...etic flowmeter 3 Electrical Installation User Guide OI FET2XX EN Rev E 17 Fig 3 2 AquaMaster 3 Transmitter Mounted in a Chamber Battery Version Shown Fig 3 3 AquaMaster 3 Transmitter Mounted in a Cabinet Battery Version Shown ...

Page 20: ... screwed cap A on the sensor connector 2 Gently push the sensor plug B into the socket and rotate it until it engages then tighten the locking ring Note Refer to Section Fig 3 4 page 25 for MODBUS connection Note If the sensor cable is terminated with fly leads connection is via a sensor cable adapter box part number WABC2035 available separately Fig 3 4 Sensor Connections A B ...

Page 21: ...I FET2XX EN Rev E 19 3 2 2 Use of Tamper detection Seals Referring to Fig 3 5 1 Pass the wire of the seal through both the hole in the locking ring and the matching hole in the front of the transmitter 2 Close the seal Fig 3 5 Use of Tamper Detection Seals Security Tag and Seal ...

Page 22: ...separated from all other AquaMaster 3 connections Capacitive loads must be inrush current limited Fully floating pulse outputs may be subject to static damage for example connecting to a floating datalogger unless COM is operated within its galvanic isolation range 35 V from earth Fig 3 6 Frequency Output Connections Note Outputs 1 and 2 are not polarity sensitive The common connection for these o...

Page 23: ...tputs is designated COM Fig 3 8 Input Output Connectons Pin Signal Function Color Output Cable A Not used Not used Violet B DATA ScanReader Data Blue C O P COM Output Common Yellow D O P2 Reverse Pulses or Direction Indicator Red E O P3 Alarm Output Brown F O P1 Forward Pulses or Forward Reverse Pulses Orange G 0V Scanreader 0V Screen Table 3 1 Connector Input Output Connections Common Alarm Input...

Page 24: ...uch voltages result in far higher power consumption from the battery or backup source limiting battery backup life Fig 3 10 RS232 Local Computer Connections Note The serial port connection shares the same physical port as the MODBUS connection so depending on cable design it may be necessary to disconnect the MODBUS connection temporarily to enable configuration of AquaMaster 3 Reading Pad 3 Wire ...

Page 25: ...ional Optional pressure transducer cables are available for a range of pressures and cable lengths Fig 3 11 Optional Pressure Transducer Connector Caution Use only the pressure transducer supplied with the transmitter Use of other pressure transducers requires alteration of the pressure span and zero factors in the transmitter ...

Page 26: ... to prevent login through any communication means and modification of any parameters on the AquaMaster 3 Fig 3 12 Read only Switch Connections Note For MID installations the meter must be ordered with the MID calibration option A Not used B Not used C Not used D Not used E Read only switch link F Read only switch link To force the transmitter into read only state link connections E F or fit adapte...

Page 27: ...ed in the following external publications MODBUS over Serial Line Specification and Implementation Guide V1 02 Dec 20 2006 http www modbus org Refer to this guide for hardware cabling grounding and shielding on MODBUS MODBUS Application Protocol Specification V1 1b Dec 28 2006 http www modbus org Note A USB Comms lead driver is required when using WEBC2101 download from www ftdichip com FTDrivers ...

Page 28: ...gnal immunity to noise pick up if the data is to be taken over long distances 3 4 3 Pull up and Pull down Resistors Polarization To prevent false triggering of slaves when the master host computer is inactive pull up and pull down resistors must be fitted to the RS485 interface at the host computer see Fig 3 15 Fig 3 14 General 2 Wire Topology Fig 3 15 Host Computer Interface Master 5 V Slave n Sl...

Page 29: ...ge the maximum length is 1000 m 3280 ft Where 4 wire cabling is used as a 2 wire cabling system the maximum length must be divided by 2 The tap cables must be short never more than 20 m 65 6 ft If a multi port tap is used with n derivations each one must have a maximum length of 40 m 131 ft divided by n The maximum serial data transmission line length for RS485 systems is 1200 m 3937 ft The length...

Page 30: ...ordance with relevant national and local standards Note Power supply connections earthing arrangements are identical for cathodically protected remote transmitter systems For cathodically protected integral transmitter systems follow cathodic installation practices AquaMaster 3 has 3 power supply options Mains power see Section 3 5 1 Battery power see Section 3 5 2 page 29 Renewable energy see Sec...

Page 31: ...ter 3 can be supplied with an optional battery pack Note Before making connections check the Data label to confirm power supply requirements AquaMaster 3 can be powered from Explorer style battery packs fitted with the MIL plastic style plug The Explorer battery capacity is 6 7 of published life Fig 3 18 Connecting a Battery Supply ...

Page 32: ...tput regulator can be omitted if the off load voltage is below V in max Renewable energy generators do not operate at maximum capacity e g low wind speeds coating of the solar panel with dust and wildlife droppings short daylight periods in winter etc For these reasons in some installations generators with a capacity greater then the specified 5 W minimum should be used Contact ABB for a technical...

Page 33: ...tery pack used by AquaMaster 3 may present a risk of fire or chemical burns if mistreated Do not recharge disassemble heat above 100 C 212 F or incinerate Replace battery pack with an ABB supplied part only Use of another battery may present a risk of fire or explosion Dispose of all battery packs promptly Keep away from children Dispose of battery packs in accordance with local regulations Where ...

Page 34: ...of display measurements 4 3 Display Information Note To use local or remote serial communications for instructions on how to alter the displayed set of measurements and for meter setup refer to COI FET2XX EN Fig 4 1 AquaMaster 3 Display Information kPa AB ML 1 2 Lower Display Time Flow Velocity Pressure Low Battery Sensor Fault Empty Pipe Condition Mains Failure Low GSM Radio Signal Renewable Ener...

Page 35: ...rvice life for the plugs and sockets on AquaMaster 3 Flow Transmitters ABB recommend regular treatment of the gold connector pins 4 4 1 Service Intervals Treat all connectors at 3 year intervals when the battery pack is changed when the installation is visited for other reasons such as CalMaster 2 Verification Fig 4 2 Transmitter Sockets MIL Style Connectors ...

Page 36: ...cap unused connectors Description Part No DeoxIT Contact Cleaner Rejuvenator DeoxIT Mini spray 5 solution flushing action 14 g Applications 150 approx D5MS 15 DeoxIT GOLD Contact Enhancer conditioner Protector DeoxIT GOLD G5 Mini Spray 5 solution 14 g flushing action and safe on plastics Applications 150 approx G5MS S Item Precaution Real time Clock This procedure may result in the loss of the rea...

Page 37: ...ctions and cables 4 4 6 Stage 1 Oxide Removal and Cleaning To remove existing oxide and clean the pins 1 Apply a short burst around 0 5 s duration of DeoxIT DN5 spray to the metal surfaces of the connectors and to the gold connector pins 2 Connect a corresponding male female connector to the connector under test 5 times 3 Wait 10 seconds 4 Reapply one short burst around 0 5 s duration of DeoxIT DN...

Page 38: ...e metal surfaces 4 Allow any residue to run out of connector 5 Wait 30 seconds for the application to dry 4 4 8 Completion Tasks To complete servicing of the plugs and sockets 1 Reconnect peripheral devices in this order a Sensor b Pressure transducer if fitted c Outputs d Communications e Battery pack power 2 Refit protective caps on unused connection sockets 3 For transmitters with built in logg...

Page 39: ... Sensor cable assembly 70 m 229 6 ft for remote WABC2010 80 Sensor cable assembly 80 m 262 4 ft for remote WABC2010 01 Output cable 1 m 3 3 ft wire ended WEBC2011 M Output cable for Technolog Cello MIL WEBC2012 M Output cable for Technolog Cello Brad Harrsion WEBC2013 M Output cable for RADCOM Multilog WEBC2014 M Output cable for Primayer Xilog WEBC2006 M Output cable 2x19 way MIL WEBC2024 Connect...

Page 40: ...7 0 64 2 81 0 4 1 76 250 1 4 40 0 63 2 77 160 100 4 200 880 160 700 9 4 41 38 1 0 4 4 0 64 2 81 250 1 6 7 04 1 4 40 160 125 5 200 880 160 700 9 4 41 38 1 0 4 4 0 64 2 81 250 1 6 7 04 1 4 40 160 150 6 500 2200 400 1760 23 5 103 46 2 56 11 27 1 6 7 04 250 4 17 61 2 5 11 160 200 8 788 3470 630 2770 37 162 90 4 0 17 61 2 5 8 8 250 6 3 27 73 3 9 17 17 160 250 10 1250 5500 1000 4400 60 260 6 4 28 18 4 1...

Page 41: ...0 0 10 0 44 160 40 50 220 40 176 2 7 11 9 0 4 1 76 0 25 1 10 160 50 79 348 63 277 4 2 18 5 0 63 2 77 0 4 1 76 160 65 125 550 100 440 6 7 29 5 1 0 4 40 0 63 2 77 160 80 200 880 160 704 10 7 47 1 1 6 7 04 1 0 4 40 160 100 313 1378 250 1100 16 7 73 5 2 5 11 00 1 6 7 04 160 150 788 3469 630 2733 42 184 9 6 3 27 73 3 9 17 2 160 200 1 250 5503 1 000 4402 67 294 9 10 0 44 02 6 3 27 73 160 250 2 000 8805 ...

Page 42: ...4 1 76 0 25 1 10 400 100 4 200 880 160 700 4 6 20 25 0 41 1 8 0 25 1 10 630 0 64 2 82 0 4 1 76 400 125 5 200 880 160 700 4 6 20 25 0 41 1 8 0 25 1 10 630 0 64 2 82 0 4 1 76 400 150 6 500 2200 400 1760 11 4 50 19 1 4 0 63 12 77 630 1 6 7 04 1 0 4 40 400 200 8 788 3470 630 2770 18 79 25 1 6 7 1 0 4 40 630 2 5 11 1 6 7 04 400 250 10 1250 5500 1000 4400 29 127 7 2 5 11 1 6 7 04 630 4 17 6 2 5 11 400 3...

Page 43: ...5 0 22 315 40 50 220 40 176 4 17 6 0 2 0 88 0 13 0 57 315 50 79 348 63 277 6 3 27 7 0 32 1 41 0 20 0 88 315 65 125 550 100 440 10 44 0 5 2 20 0 32 1 41 315 80 200 880 160 704 16 70 4 0 81 3 56 0 51 2 24 315 100 313 1378 250 1100 25 110 1 3 5 72 0 79 3 47 315 150 788 3469 630 2733 63 277 3 2 14 09 2 0 8 80 315 200 1 250 5503 1 000 4402 100 440 5 1 22 45 3 2 14 09 315 250 2 000 8805 1 600 7044 160 7...

Page 44: ...onnections MM GA 15 mm ISO 228 G 3 4 in B 3 4 in NPSM 20 mm ISO 228 G 1 in B 1 in NPSM 25 mm ISO 228 G 11 4 in B 11 4 in NPSM 40 to 300 mm 1 5 to 12 in flanged MM GA EN1092 1 ISO 7005 PN10 PN16 ANSI B16 5 Class 150 AS 2129 Tables C D E and F AS 4087 PN14 PN16 PN21 JIS to BS2210 10k 350 to 600 mm 14 to 24 in flanged MM GA EN1092 1 ISO 7005 PN10 PN16 AS 4087 PN14 PN16 PN21 AS 2129 Tables C D JIS to ...

Page 45: ...ypically 5 years Battery life is shorter with GSM depending on how frequently it is used and for what period For example used once per day for SMS automated reporting of data logged at 15 minute intervals the life of a battery pack would be typically reduced by 20 Backup power time Approximately 1 minute Pulse and alarm outputs Three bidirectional solid state switches with common isolation 35 V DC...

Page 46: ...h integral antenna under water General advice is to mount the antenna as high as possible always outside of any metal enclosure and not under the surface of the ground Pressure system external transducer option Pressure range 16 bar Abs Connection Standard quick fit male probe connector via an adapter cable Operating temperature range 20 ambient to 70 C 4 to 158 F Protect the sample and transducer...

Page 47: ...Guide OI FET2XX EN Rev E 45 Mounting Pipe conditions Pressure loss MM GA only Flow Rate Pressure Loss in bar psi Q3 0 63 9 1 Q3 2 0 16 2 3 Sensor Electrodes 45 Maximum Flow Direction 0 x pipe dia minimum 0 x pipe dia minimum MM GA 5 x pipe dia 2 x pipe dia MM GF ...

Page 48: ...iffs Net Flow Totals No of Records 8831 11361 732 Logging Interval 15 to 65500 s adjustable 24 hr fixed Typical Capacity 3 months 15 min 7 days approx 1 min 2 year Software Direct RS232 SMS Text ABB AC800M ABB Generic for example LogMaster ABB Logger Server AMI Areal Topkapi AutoChart EcoTech HydroComp Mobile phone text OSI PI Database or Capula Primayer Primeware Primayer Xilog QTech Technolog PM...

Page 49: ...tion Nominal Dimensions 15 to 25 mm 1 2 to 1 in Screw Ends MM GA Meter Size Dimensions mm in Approx Weight mm in A Connection kg lb 15 1 2 119 4 7 G 3 4 in B or 3 4 in NPSM 2 5 5 20 3 4 127 5 G 1 in B or 1 in NPSM 2 5 5 25 1 127 5 G 11 4 in B or 11 4 in NPSM 2 5 5 Dimensions in mm in A 61 2 4 128 5 89 3 5 ...

Page 50: ...mensions mm in Approx Weight mm in A B kg lb 40 11 2 150 5 9 200 7 9 11 24 50 2 165 6 5 200 7 9 12 27 65 21 2 219 8 6 200 7 9 13 29 80 3 200 7 9 200 7 9 18 40 100 4 220 8 6 250 9 8 25 55 125 4 220 8 6 250 9 8 25 55 150 6 285 11 2 300 11 8 31 68 200 8 340 13 3 350 13 8 48 106 250 10 405 15 9 450 17 7 75 165 300 12 460 18 1 500 19 7 112 247 B A ...

Page 51: ...4 to 24 in Flanged MM GA Meter Size Dimensions mm in Approx Weight mm in A B C kg lb 350 14 513 20 2 520 20 5 550 21 7 100 220 400 16 570 22 4 576 22 7 600 23 6 115 253 450 18 632 24 9 627 24 7 698 27 5 160 352 500 20 686 27 0 679 26 7 768 30 2 217 455 600 24 772 30 4 770 30 3 918 36 1 315 693 C A B 50 A ...

Page 52: ...ter Size Dimensions mm in Approx Weight mm in A B kg lb 25 1 115 4 5 200 7 9 7 15 40 11 2 150 5 9 200 7 9 9 20 50 2 165 6 5 200 7 9 10 23 65 21 2 185 7 3 200 7 9 18 40 80 3 200 7 9 200 7 9 18 40 100 4 230 9 0 250 9 8 24 54 150 6 285 11 2 300 11 8 38 84 200 8 345 13 6 350 13 8 37 81 250 10 410 16 1 450 17 7 60 132 300 12 485 19 1 500 19 7 70 154 B A ...

Page 53: ...re boarding an aircraft Remove the SIM card before shipping Make sure it cannot be switched on inadvertently The operation of wireless appliances in an aircraft is forbidden to prevent interference with communications systems Failure to observe these instructions may lead to the suspension or denial of cellular services to the offender legal action or both 3 Do not operate the cellular terminal or...

Page 54: ...AquaMaster 3 Electromagnetic flowmeter Notes 52 User Guide OI FET2XX EN Rev E Notes ...

Page 55: ...Analytics Instrumentation pH Conductivity and Dissolved Oxygen Transmitters and Sensors Ammonia Nitrate Phosphate Silica Sodium Chloride Fluoride Dissolved Oxygen and Hydrazine Analyzers Zirconia Oxygen Analyzers Katharometers Hydrogen Purity and Purge gas Monitors Thermal Conductivity Customer support We provide a comprehensive after sales service via a Worldwide Service Organization Contact one ...

Page 56: ...production disclosure to third parties or utilization of its contents in whole or in parts is forbidden without prior written consent of ABB Copyright 2011 ABB All rights reserved 3KXF208200R4201 Capula is a copyright of Capula Limited 2010 EcoTech is a registered trademark of EcoTech Pty Ltd HydroComp is a copyright of HydroComp Inc 2010 Microsoft Excel and Windows are registered trademarks of th...

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