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ABB AquaProbe 2, Installation Manual

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Insertion-Type Electromagnetic Probe Flowmeter

AquaProbe 2

Notes

38

IM/AP

 Issue 9

Notes 

Summary of Contents for AquaProbe 2

Page 1: ...Installation Guide IM AP Issue 9 Insertion Type Electromagnetic Probe Flowmeter AquaProbe 2 ...

Page 2: ...ovative 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 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 speci...

Page 3: ...ipe Diameters 1m 2m 40in 80in 14 2 6 3 Mean Axial Velocity Method 15 2 7 AquaProbe Alignment 16 3 Electrical Installation 17 3 1 Connections 17 3 1 1 Sensor Terminal Box Connections Remote Versions only 17 3 1 2 Environmental Protection 18 3 1 3 Transmitter Connections 19 3 2 Input Output Connections 21 3 2 1 Frequency Outputs 21 3 2 2 PLC Interface 22 3 2 3 MIL Connector Input Output Connections ...

Page 4: ...32 5 1 Fitting the Battery 32 5 2 Start up 32 5 3 Display Activation 33 5 4 Replacing the Battery 34 Appendix A 35 A 1 Testing the Flow Profile for Symmetry 35 A 1 1 Partial Velocity Traverse 35 A 1 2 Single Entry Point Method 35 A 1 3 Dual Entry Point Method 36 Appendix B Aquamaster Block Diagram 37 Notes 38 ...

Page 5: ...as leakage monitoring and network analysis and in permanent locations where cost or space limitations preclude the use of conventional closed pipe meters 1 1 System Schematic Note The tip of the AquaProbe is a precision built part of the equipment and must be handled with care When the AquaProbe is not in use fully retract the tip of the probe and replace the end cap When removing inserting the pr...

Page 6: ...n 4 IM AP Issue 9 2 Mechanical Installation 2 1 Location Environmental Conditions 2 1 1 AquaProbe Fig 2 1 Environmental Requirements AquaProbe 60 C 140 F Maximum 20 C 4 F Minimum A Within Temperature Limits C Avoid Excessive Vibration 10m 30ft B Within Environmental Rating IP68 NEMA 6 ...

Page 7: ...llation IM AP Issue 9 5 2 1 2 Transmitter Fig 2 2 Environmental Requirements AquaMaster Transmitter AquaMaster 20 C 4 F Minimum 60 C 140 F Maximum A Within Temperature Limits C Shade from Heat AquaMaster AquaMaster 1 5m 60in IP68 NEMA 6 ENCLOSURE 6P B Within Environmental Rating ...

Page 8: ...velocity at a single point Several conditions must be fulfilled to validate the method which uses calculations based on empirical data Where the validating conditions can be met the method described in Section 2 2 is the most practical It is possible to measure the velocity either on the centre line which reduces sensitivity to positional errors or at the assumed point of mean flow velocity Table ...

Page 9: ... from the measuring cross section Minimum upstream straight length For a measurement at the point of mean axial velocity For a measurement on the axis of the conduit 90 elbow or a t bend Several 90 coplanar bends Several 90 non coplanar bends Total angle convergent 18 to 36 Total angle divergent 14 to 28 Fully opened butterfly valve Fully opened plug valve 50 50 80 30 55 45 30 25 25 50 10 25 25 15...

Page 10: ...Velocity in m s Maximum Velocity in ft s Pipe Size in mm 0 1000 2000 3000 4000 5000 6000 7000 8000 0 3 0 7 0 10 0 13 0 17 0 20 0 0 1 0 2 0 3 0 4 0 5 0 6 0 40 80 120 160 200 240 280 320 Mean Axial Velocity Method 1 8 Diameter Insertion Length in mm Maximum Velocity in m s Maximum Velocity in ft s Insertion Length in inches 0 1 0 2 0 3 0 4 0 5 0 6 0 0 3 0 7 0 10 0 13 0 17 0 20 0 4 8 12 16 20 24 28 3...

Page 11: ... 2 3 Location Mechanical 2 3 1 AquaProbe Note Pipeline recommended to be metal for electrical screening Fig 2 7 Mechanical Requirements AquaProbe 320mm 12 5in 1in BSP 1 5in BSP 1in NPT 900 1100 1300 or 1600 mm 36 44 52 or 63in B Orientation A Clearance Dimensions On Centre Line O n C e n t r e L i n e ...

Page 12: ...nsions Transmitter AquaMaster 170mm 6 7in 140mm 5 5in Installation and wiring access 300mm min 450mm preferred Allowance for cable bend 130mm Standard 200mm Armoured Allowance for cable bend 130mm Standard 200mm Armoured 146 0mm 125 0mm ø6 0mm ø12mm ø6 0mm Transmitter Mounting Plate Details 150 mm Transmitter Mounting Plate 170mm 6 7in 170 mm ...

Page 13: ...d with a safety mechanism see Fig 2 9A which should be attached to its securing collar as shown in Fig 2 9B This prevents rapid outward movement by the probe if the nut 1 is released Note To ensure maximum safety the positioning collar MUST be tightened in place using a 4mm hexagon key Fig 2 9 Safety Mechanism See Warning A Unsecured B Secured 1 ...

Page 14: ... or removing the AquaProbe suitable restraining equipment must be used to prevent the probe being forced out under pressure Ensure that the valve is fully open Fig 2 10 Insertion Bore Clearance Fig 2 11 Installing the AquaProbe 25mm 1in Minimum Clearance Apply PTFE Tape Remove Cap Tighten hand tight only Insert Probe Into Valve Tighten Firmly 1 3 4 5 2 ...

Page 15: ... out under pressure Ensure that the valve is fully open Note Safety restraint omitted for clarity Fig 2 12 Setting the insertion Depth Centre Line Method for Pipe Diameters 1m 40in 1 2 9 Open Fully Lower probe to touch bottom of pipe Retract probe fully Slide positioning collar down to nut and lock Slacken Tighten to 40Nm 30ft lbf Determine internal diameter D Unlock slide positioning collar down ...

Page 16: ...the valve is fully open Note Safety restraint omitted for clarity Fig 2 13 Setting the Insertion Depth Centre Line Method for Pipe Diameters 1m 2m 40in 80in Measure to top of valve plate VP Open Fully Lower probe to touch valve plate Retract probe fully Slide positioning collar down to nut and lock Slacken Tighten to 40Nm 30ft lbf Determine internal diameter D Insert probe to position collar depth...

Page 17: ...he valve is fully open Note Safety restraint omitted for clarity Fig 2 14 Setting the Insertion Depth Mean Axial Velocity Method Measure to top of valve plate VP Determine internal diameter D Open Fully Lower probe to touch valve plate Retract probe fully Slide positioning collar down to nut and lock Slacken Tighten to 40Nm 30ft lbf Insert probe to position collar depth D 8 Unlock slide positionin...

Page 18: ...ng the AquaProbe suitable restraining equipment must be used to prevent the probe being forced out under pressure Ensure that the valve is fully open Note Safety restraint omitted for clarity Note Measurement error due to misalignment of 2 is 0 15 Fig 2 15 Probe Alignment Align parallel to pipe within 2 see Notes Slacken Tighten 40Nm 30ft lbf 1 3 2 See Notes ...

Page 19: ...ee screen wires together and sleeve them Twist cable pairs together Maintain Environmental Protection at all times Conduit connections must provide cable entry sealing Fig 3 1 Sensor Terminal Box Connections Remote Version Caution With Belden Cable 8777 ensure that the black wires are not interchanged and remain with the associated twisted pair CABLE ABB Belden 8777 Violet White Blue Black Green S...

Page 20: ...fety precautions Read the manufacturers instructions carefully before preparing the potting material The remote sensor terminal box connections must be potted immediately on completion to prevent the ingress of moisture Check all connections before potting see section 3 page 17 Do not overfill or allow the potting material to come into contact with O rings or grooves Do not let potting material en...

Page 21: ...ure cable glands seal use cable of diameter 7 to 11mm 0 28 to 0 43 in only Ensure cable glands are tightened after wiring Ensure that O ring seals and mating surfaces are clean to maintain environmental rating Fig 3 3 Transmitter Connection Terminal Access Fig 3 4 Transmitter Connection Glands Conduit Entry Slacken captive screws Remove Cover 2 1 ...

Page 22: ...ntain Environmental Protection at all times Conduit connections must provide cable entry sealing Fig 3 5 Sensor Cable Connections Gland Conduit Remote version Fig 3 6 Sensor Cable Connections Connector Remote version Note This arrangement is an option 1 7 AquaMaster Transmitter 1 Brown 2 Red 3 Orange 4 Yellow 5 Sleeved Ground 6 Blue 7 Violet 1 Black 2 Green 3 Black 4 Red 5 Sleeved Ground 6 Black 7...

Page 23: ...Capacitive loads must be inrush current limited Fig 3 7 Frequency Output Connections Note Outputs 1 2 3 are not polarity sensitive The common connection for these outputs is designated COM d c supply Counter Totalisers Forward Flow Reverse Flow and or 1 2 3 4 5 6 1 2 3 4 5 6 AquaMaster Transmitter COM O P1 Telemetry Electronic Counters etc Counter Totalisers Forward Flow and or Reverse Flow 1 2 3 ...

Page 24: ... 2 2 PLC Interface Fig 3 8 Frequency and Alarm Output Connections Note Outputs 1 2 3 are not polarity sensitive The common connection for these outputs is designated COM Output 3 is an option and may not function on some models AquaMaster Transmitter Common Input 1 Input 2 Input 3 PLC COM O P1 O P2 O P3 ...

Page 25: ...3 Output 3 White Orange F O P 2 Reverse Pulses or Direction Blue G O P Com Common Drain Wire H Reserved J I P Gnd Input Common White K I P Contact Input Violet L RXD Receive data serial input connection Turquoise M TXD Transmit data serial output connection Brown N RTS Request to send Red Black P CTS Clear to send Yellow Red R Reserved S Reserved T RI Ring Indicator Yellow U Reserved V Serial GND ...

Page 26: ...robe Flowmeter AquaProbe 2 3 Electrical Installation 24 IM AP Issue 9 3 2 4 Local Computer Connection Fig 3 10 Local Computer Connections Connected to 9 pin Serial Data socket on PDA or PC via Laplink lead ABB Limited Part No WEBC2000 ...

Page 27: ...te Computer Connection Option Fig 3 11 RS232 Connections AquaMaster Terminal RS232 9 PIN PC Connector 25 PIN PC Connector TXD TXD 3 2 RXD RXD 2 3 RTS RTS 7 4 CTS CTS 8 5 RI RI 9 22 GND GND 5 7 Table 3 2 RS232 Connections Modem Radio Modem Radio Pad Computer or similar AquaMaster Transmitter RTS RXD TXD GND RI CTS ...

Page 28: ...must be in accordance with relevant national and local standards Note Power Supply connections earthing arrangements are identical for Cathodically Protected systems Fig 3 12 Power Supply Connections A C Version Transmitter Internal External Transmitter End View 4mm2 10 A W G Copper Wire METER CODE LOG CODE SERIAL TAG Made in UK ENCLOSURE 6P IP68 A C power via a suitable isolator and fuse Limited ...

Page 29: ...allation IM AP Issue 9 27 Fig 3 13 Power Supply Connections D C Version Transmitter Internal External Transmitter End View 4mm2 10 A W G Copper Wire METER CODE LOG CODE SERIAL TAG Made in UK ENCLOSURE 6P IP68 D C Supply Limited SUPPLY Transmitter Label AquaMaster Transmitter E ...

Page 30: ...or a range of pressures and cable lengths Caution Ensure that only the pressure transducer supplied with the transmitter is used Use of other pressure transducers requires alteration of the pressure span and zero factors in the transmitter see Quick Reference Programming guide Fig 3 14 AquaMaster Transmitter fitted with Optional Pressure Transducer Connector Pressure Transducer Connector ...

Page 31: ...structions carefully before preparing the potting material Fig 3 15 Potting the Transmitter Caution For increased protection against accidental water ingress for example by poor gland tightening pot the termination area Check all connections and operations before potting see section 3 page 17 Do not overfill or allow the potting material to come into contact with O rings or grooves Do not let pott...

Page 32: ...limetres by the most accurate method available 2 Determine the profile factor Fp from Fig 4 1 3 Calculate the insertion factor Fi Example for a pipe of internal diameter 593mm 23 35in Fp 0 861 derived from Fig 4 1 Fi Fi 1 021 Note Due to software configuration all calculations are in metric units Therefore if using an imperial pipe the diameter MUST be converted into millimetres 1in 25 4mm i e a 3...

Page 33: ...or Fp of 1 must be used 3 Calculate the insertion factor Fi Example for a pipe of internal diameter 593mm 23 35in Fp 1 Fi Fi 1 074 4 4 Partial Velocity Traverse Refer to the Appendix A1 for procedure 4 5 AquaProbe Transmitter Setup The AquaProbe Transmitter can be set up to display point velocity mean velocity or flow rate as required For full programming details refer to the AquaProbe Quick Refer...

Page 34: ...y window remove this film before commencing normal operation When the power is connected or the plastic film is removed the AquaMaster performs a self test operation and indicates a successful completion with EE Pass displayed If the display shows EE Fail 1 remove all power check the sensor wiring and apply power If the display shows EE Fail 2 or 3 contact ABB Warning The lithium battery used in t...

Page 35: ...anently activated To alter the displayed set of measurements or instrument setup see the Quick Reference Programming Guide Fig 5 1 Location of Controls Note For the use of local or remote serial communication and configuration see the Quick Reference Programming Guide Lower Display Time Flow Velocity Pressure Left Battery Warning Sensor Fault Empty Pipe condition Mains Failure Right Battery Warnin...

Page 36: ...ry retaining clamp and pull the connector apart 4 Remove the battery 5 Fit a new battery ABB Limited Part No WABC2001 ensuring that the end of the battery with the connection wires is pushed up against the inside end of the top cover 6 Connect the battery connector to the connector previously removed 7 Push the connection centrally behind the battery retaining clamp to secure the battery 8 Fit the...

Page 37: ...al diameter of the pipe proceed with the Dual Entry Point Method detailed in Section A 1 3 A 1 2 Single Entry Point Method 1 Insert the probe to a depth of 1 8 the pipe diameter see Fig 2 14 2 Calculate the insertion factor Fi 3 Refer to the AquaProbe Transmitter Configuration Manual and enter a Blockage Factor BL of value equal to Fi 4 Record the flow velocity reading 5 Insert the probe to a dept...

Page 38: ...value equal to Fi 4 Record the flow velocity reading 5 Insert the probe to a depth of 1 8 the pipe diameter through the second mounting boss 6 Record the flow velocity reading 7 Calculate the ratio of the two values recorded If the ratio is between 0 95 and 1 05 the flow profile is acceptable and the procedure detailed in Section 4 2 can be used If outside this ratio the AquaProbe should be resite...

Page 39: ...aster Block Diagram IM AP Issue 9 37 Appendix B Aquamaster Block Diagram Local Configuration Adaptor Display Measurement System 1 2 3 4 6 7 5 Optional Power Supply Pulse Alarm Circuits Common Main RS232 Communication Port Processor 1 2 3 4 6 7 5 Contact Input Part No WEBC2000 ...

Page 40: ...Insertion Type Electromagnetic Probe Flowmeter AquaProbe 2 Notes 38 IM AP Issue 9 Notes ...

Page 41: ...Insertion Type Electromagnetic Probe Flowmeter AquaProbe 2 Notes IM AP Issue 9 39 ...

Page 42: ...Insertion Type Electromagnetic Probe Flowmeter AquaProbe 2 Notes 40 IM AP Issue 9 ...

Page 43: ...umentation 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 of the followin...

Page 44: ...nuous product improvement and the right is reserved to modify the information contained herein without notice Printed in UK 04 07 ABB 2007 ABB Limited Oldends Lane Stonehouse Gloucestershire GL10 3TA UK Tel 44 0 1453 826661 Fax 44 0 1453 829671 ABB Inc 125 E County Line Road Warminster PA 18974 USA Tel 1 215 674 6000 Fax 1 215 674 7183 ...

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