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ABB CalMaster2 Instruction Manual Download Page 6

Field and Software Tools

CalMaster2 and CheckMaster

1 Introduction

4

IM/VCM2

Issue 6

1.1 CalMaster2 Options

There are two options of CalMaster2 available:

„

CalMaster IRIS

Enables the printing of service reports and certification to within 1% of factory calibration
(fingerprinted flow meters) or 2% (non-fingerprinted flow meters). Predictive diagnostics are
also provided to provide early warning of a possible system failure, enabling maintenance
engineers to anticipate problems and take planned remedial action in advance.

CalMaster2 comprises:

–

CalMaster IRIS Verification Tool

–

Enhanced IRIS Software

„

CheckMaster

Enables the validation of flow meters and the printing of a service report.

CheckMaster comprises:

–

CheckMaster Validation Tool

–

IRIS  Software

The functions available for each option are:

CheckMaster

CalMaster IRIS

Page

Install Factory Files

34

Transmitter Wizard

32

CalMaster2 Wizard

27

Flowmeter Calibration Verification Report

35

Flowmeter Conformance Report

35

Trend Analysis

36

Table 1.1 CalMaster2 Options

Summary of Contents for CalMaster2

Page 1: ...Instruction Manual IM VCM2 Issue 6 Field and Software Tools CalMaster2 and CheckMaster ...

Page 2: ...f 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 Publications Department 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 p...

Page 3: ...sor Leads 12 3 3 2 Removing the AquaMaster Cover 12 3 3 3 Fitting an AquaMaster Sensor Socket 13 3 3 4 Fitting an AquaMaster Pulsed Output Socket 14 3 3 5 Fitting an AquaMaster Pulsed Output Socket with Serial Communications 15 3 3 6 Fitting an Adaptor Box to the Sensor Cable 16 3 3 7 Adaptor Box Environmental Protection 16 3 3 8 Connecting an AquaMaster with MIL Connectors to a CalMaster2 17 3 3 ...

Page 4: ...29 5 5 Transmitter Wizard 32 5 5 1 New Edit Configuration 33 5 6 Factory Fingerprint Files 34 5 7 Print a Conformance Report or Verification Certificate 35 5 8 Trend Analysis 36 5 8 1 Scale Tab 37 5 8 2 Names Tab 37 5 8 3 Statistics Tab 38 5 8 4 Data Filter Tab 38 5 9 CalMaster2 Database 39 6 Recharging CalMaster2 40 7 Registration 41 7 1 Registering Flowmeters 43 7 2 Downloading Fingerprint Files...

Page 5: ...nt tests Test of sensor magnetic properties Digital output test Analog output test The CalMaster IRIS CheckMaster see Section 1 1 page 4 test box displays the results of each test during the testing sequence At the end of each test a record is stored locally within the test box Up to 100 test results can be stored Once the CheckMaster CalMaster2 test box is connected to a PC that is running the Ca...

Page 6: ...stem failure enabling maintenance engineers to anticipate problems and take planned remedial action in advance CalMaster2 comprises CalMaster IRIS Verification Tool Enhanced IRIS Software CheckMaster Enables the validation of flow meters and the printing of a service report CheckMaster comprises CheckMaster Validation Tool IRIS Software The functions available for each option are CheckMaster CalMa...

Page 7: ...ed with the CalMaster2 are CalMaster2 IRIS Software CD ROM This Instruction Manual Universal mains adaptor and in car adaptor 5 MagMaster adaptor kits Part no WADX0089 see Fig 2 1 Connection Leads see Section 2 1 1 page 6 Note Recharge the CalMaster2 before first use see Section 6 page 40 Fig 2 1 MagMaster Adaptor Kit MagMaster VKE Adaptor Board Sensor Cable Plug ...

Page 8: ...Connector Leads Green numeric sleeves AquaMaster Explorer Leads Red numeric sleeves Communications Lead 1 WEBC0221 RS232 Serial Communications Lead WEBC2000 Communications Lead 3 WEBC0221 T MagMaster Transmitter Lead 2 WEBC0212 MagMaster Sensor Lead 3 WEBC0213 MagMaster Transmitter Lead 2 WEBC0211 AquaMaster MIL Sensor Cable WEBC0233 AquaMaster 19 way Output Cable WEBC0235 AquaMaster 7 way Output ...

Page 9: ... Software The first time the CalMaster2 IRIS software is used a registration screen appears To register the CalMaster2 IRIS software 1 Type the User name Company name and Customer identification number 2 Select to either create a PDF of the registration or send the details by email To create a PDF select the Create a pdf file for printing or faxing check box To send an email leave the Create a pdf...

Page 10: ... CalMaster Helpline Oldends Lane Stonehouse Gloucestershire GL10 3TA UK or Fax it to 44 0 1453 829671 4 Click Close to exit CalMaster2 3 1 2 Unlocking CalMaster2 When the registration e mail or letter is received from ABB 1 Copy the registration number provided and start the CalMaster2 IRIS software The Registration dialog box appears 2 Paste the registration number into the text box and click Nex...

Page 11: ...tter for testing at any time Extra adaptor kits are available part no WADX0089 To enable a hard wired MagMaster system to be tested by the CalMaster2 it may be necessary to fit a small adaptor board see Section 3 2 1 page 10 to the MagMaster To remove the MagMaster covers 1 Slide the cover down A 2 Pull out slightly and slide off B 3 Slacken the captive screws C 4 Remove the protective cover D Not...

Page 12: ...screws 4 Fit and tighten the securing screw to the corner of the adaptor board 5 Connect the sensor cable leads to the adaptor plug see Fig 3 3 Do not fit the plug to the socket on the adaptor board Note The newer series VKH MagMaster does not need to have this adaptor board fitted as one is already incorporated into its design Fig 3 2 Fitting the Adaptor Board Fig 3 3 Fitting the Sensor Cable Plu...

Page 13: ...RM 1 F OUT A ALARM 2 F OUT B PLS OV PLS OV EXT I P EXT I P TX SIG RX SIG TX SIG RX SIG OVC N L 1 2 3 Yellow 12 Red 11 Red 12 Yellow 12 Red 1 Yellow 1 Connect the communication lead to the appropriate terminals FOUTA Red FOUTB Blue PLS0V Black IC Yellow IC Green 1 2 3 ALARM 1 F OUT A ALARM 2 F OUT B PLS OV PLS OV EXT I P EXT I P TX SIG RX SIG TX SIG RX SIG OVC N L Yellow 2 1 2 3 ALARM 1 F OUT A ALA...

Page 14: ...ection 3 3 3 page 13 and a small adaptor box to the end of the sensor cable see Section 3 3 6 page 16 3 3 2 Removing the AquaMaster Cover To remove the AquaMaster cover 1 Slacken the captive screws A 2 Lift the cover off B 3 Press the battery tray retaining tabs and remove the battery tray C Note Hard wired AquaMasters that have been potted need to have the potting dug out carefully Re pot the Aqu...

Page 15: ... remove the covers see Section 3 3 2 page 12 2 Disconnect and withdraw the sensor cable A 3 Remove and discard the gland B 4 Feed the socket lead into the AquaMaster and fit the socket MGFA0609 S C 5 Connect the sensor cable D 6 Replace the covers see Fig 3 7 page 12 Fig 3 8 Fitting an AquaMaster Sensor Socket 1 7 B A C D Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Brown Red Orange Yellow Green Blue...

Page 16: ...er and remove the covers see Section 3 3 2 page 12 2 Disconnect and withdraw the pulsed output cable A 3 Remove and discard the gland B 4 Feed the socket lead into the AquaMaster and fit the socket MGFA0609 S C 5 Connect the sensor cable D 6 Replace the covers see Fig 3 7 page 12 Fig 3 9 Fitting an AquaMaster Pulsed Output Socket O P3 O P2 O P1 O P COM V 0V DATA Brown Red Orange Yellow Violet Gree...

Page 17: ... remove the covers see Section 3 3 2 page 12 2 Disconnect and withdraw the pulsed output cable A 3 Remove and discard the gland B 4 Feed the socket lead into the AquaMaster and fit the socket MGFA0609 O C 5 Connect the sensor cable D 6 Replace the covers see Fig 3 7 page 12 Fig 3 10 Fitting an AquaMaster Pulsed Output Socket with Serial Communications O P COM O P1 O P2 GND RI CTS RTS TXD RXD Grey ...

Page 18: ...overs 3 3 7 Adaptor Box Environmental Protection Fig 3 11 Fitting an Adaptor Box to the Sensor Cable Fig 3 12 Potting the Adaptor Box Warning Potting materials are toxic use suitable safety precautions Read the manufacturers instructions carefully before preparing the potting material Check all connections before potting see Section 3 3 6 page 16 Do not overfill or allow the potting material to co...

Page 19: ...quaMaster with MIL Connectors to a CalMaster2 To test an AquaMaster see Section 4 page 20 Fig 3 13 Fitting Communications Leads Fig 3 14 Fitting Transmitter Leads Fig 3 15 Fitting Sensor Leads 1 2 3 7 way MIL or 19 way MIL Red 1 Yellow 1 Red 11 Red 1 Yellow 1 Green 12 1 2 3 Red 2 Green 2 1 2 3 Red 3 Green 3 ...

Page 20: ...Master with a Sensor Adaptor Box to a CalMaster2 To test an AquaMaster see Section 4 page 20 Fig 3 16 Fitting Communications Leads Fig 3 17 Fitting Transmitter Leads Fig 3 18 Fitting Sensor Leads 1 2 3 7 way MIL or 19 way MIL Red 1 Yellow 1 Red 11 Red 1 Yellow 1 Green 12 1 2 3 Red 2 Green 2 1 2 3 Red 3 Green 3 ...

Page 21: ...ion 3 4 1 Connecting an AquaMaster Explorer to a CalMaster2 To test an AquaMaster Explorer see Section 4 page 20 Fig 3 19 Fitting Communications Leads Fig 3 20 Fitting Transmitter Leads Fig 3 21 Fitting Sensor Leads AquaMaster 1 2 3 1 2 3 Red 1 Yellow 1 Red 11 Red 12 Yellow 12 Red 1 1 2 3 AquaMaster Red 2 1 2 3 Red 3 ...

Page 22: ...nnection has been established a prompt appears to select whether the pipe is full 7 Select Yes or No A prompt appears to test the analog outputs Note If there is insufficient battery charge to completely a test CalMaster2 does not start the test Recharge the CalMaster2 see Section 6 page 40 If the ambient temperature is greater than the specified operating temperature of 50 C 122 F the tests are f...

Page 23: ...meter that does not have an associated fingerprint file it must find a valid test that can be used as a reference A screen appears stating that CalMaster2 is searching for a reference test Note This screen appears for 10 seconds before proceeding automatically to the next test 1 Select Retry 2 If the test fails again either press Retry to test again or Ok to continue to the next test Note This scr...

Page 24: ...provided see Fig 4 1 It is recommended that the CalMaster2 is connected to the power supply while downloading see Section 6 page 40 To connect CalMaster2 to a computer 1 Slide the cover A down to reveal the serial port 2 Connect the RS232 cable to the CalMaster2 B 3 Connect the RS232 cable to the computer C Caution If there is insufficient battery charge to completely a download there is a chance ...

Page 25: ...24 To Download Verifications 1 Start the CalMaster2 IRIS software The CalMaster2 Wizard appears 2 Select Process Records and click Next 3 Follow the instructions for processing records see Section 5 4 1 page 28 Note Once the verifications have been downloaded the CalMaster2 does not need to be connected to be able to use it to view organize and print reports of the verifications ...

Page 26: ...FingerPrint comparison analysis using Fuzzy Logic routines In order to generate a certificate a software password is required 5 2 CalMaster2 IRIS Interface To open CalMaster2 either select Start Programs ABB CalMaster2 CalMaster2 or double click the CalMaster2 IRIS shortcut icon on the desktop The application window appears CalMaster2 automatically detects whether a CalMaster2 is connected to the ...

Page 27: ... Section 5 3 page 26 c Toolbar The toolbar buttons provide quick access to the CalMaster2 functions d Application Area The main application window e CalMaster2 Wizard The CalMaster2 Wizard appears automatically when the software is launched see Section 5 4 page 27 f Status Bar The status bar displays the connection details of the CalMaster2 Icons Install Factory Files CalMaster2 Wizard Connection ...

Page 28: ...on to the CalMaster2 see Section 5 5 page 32 CalMaster2 Wizard Opens the CalMaster2 wizard dialog box see Section 5 4 page 27 Languages Changes the CalMaster2 language Help Contents Opens the contents page of the on line help Index Opens the CalMaster2 on line help index Search Opens the CalMaster2 on line help search facility Support Creates an e mail addressed to ABB Technical Support ABB Home P...

Page 29: ...ions that have already been downloaded Edit CalMaster2 Database lists edits the flow meters and CalMaster2s used To open the CalMaster2 Wizard 1 Either select Tools CalMaster2 Wizard or click the button The CalMaster2 Wizard dialog box appears 2 Select Process Records see Section 5 4 1 page 28 Review Records see Section 5 4 2 page 29 Records can be sorted in either alphabetical or date order Edit ...

Page 30: ...2 On the right hand side click the button to start the download process 3 At the Reset CalMaster2 task a prompt appears asking whether the CalMaster2 is to be reset Select either Yes to delete all verifications held in the CalMaster2 or No to leave the verifications in place 4 Once the download process is complete click Next The Review Records dialog box appears see Section 5 4 2 page 29 Icons Sta...

Page 31: ... processing records see Section 5 4 1 page 28 The records are sorted in alphabetical order Click the button to start the CalMaster2 wizard select Review Records and click Next Records can be sorted in either alphabetical or date order The Review Records dialog box has two tabs CheckMaster and CalMaster2 Depending on your licence one of these tabs may be disabled The right hand toolbar has three bu...

Page 32: ...ion 5 7 page 35 Icons The first verification that has passed This is used as the benchmark for all other verifications Verifications that have passed Verifications that are marginal or have passed but near the limits of the Fuzzy Logic see page 24 Verifications that have one or more failed tests Each verification can be expanded to display the individual tests The results of each test are displaye...

Page 33: ... manufactured Verifications that have passed Verifications that have one or more failed tests Verifications that are marginal or have passed but near the limits of the fuzzy logic Each verification can be expanded to display the individual tests The results of each test are displayed in the right hand pane Individual tests are marked as Passed Passed although the fuzzy logic is marginal Passed alt...

Page 34: ... is displayed in the list The right hand toolbar has five buttons New Opens the add New Edit Configuration dialog box see Section 5 5 1 page 33 Delete Deletes the selected configuration Edit Opens the selected configuration Connect Connects to CalMaster2 Open Opens a saved device configuration file Save Saves the selected device as a configuration file Ok Closes the dialog box using the selected c...

Page 35: ...d and Software Tools CalMaster2 and CheckMaster 5 CalMaster2 IRIS Software IM VCM2 Issue 6 33 5 5 1 New Edit Configuration This is used to configure the associated serial port connection for the CalMaster2 ...

Page 36: ... factory test results If fingerprint files are not available verification is made to within 2 A flow meter s fingerprint file needs to be installed once only It is stored within CalMaster2 IRIS software database so that it is available whenever a verification is processed for that flow meter To install a flow meter s fingerprint file 1 Either select File Install Factory File or click the button Th...

Page 37: ... To print a Conformance Report or Verification Certificate 1 Click the button to start the CalMaster2 wizard select Review Records and click Next 2 On the right hand side of the Review Records dialog box click the report button or certificate button A print preview is displayed 3 Click the button a print dialog box appears Select a printer and click Print ...

Page 38: ... Review Records and click Next 2 On the right hand side of the Review Records dialog box click the button The trend analysis dialog box appears The graph functions are a Group Individual Tests Select whether to display an individual test or a group of tests b Test Select the test to be displayed c Graph Type Select the type of graph to be displayed Options are Data Quality Data Score and Quality S...

Page 39: ...d Software Tools CalMaster2 and CheckMaster 5 CalMaster2 IRIS Software IM VCM2 Issue 6 37 5 8 1 Scale Tab Controls the default scale for the graph 5 8 2 Names Tab Controls the color and labelling for the graph ...

Page 40: ... Tools CalMaster2 and CheckMaster 5 CalMaster2 IRIS Software 38 IM VCM2 Issue 6 5 8 3 Statistics Tab Displays basic statistics of the selected flowmeter 5 8 4 Data Filter Tab Forces the results to ignore any zero values ...

Page 41: ...e button to start the CalMaster2 wizard 2 Click Edit CalMaster2 Database the CalMaster2 Database Browser appears The Database Meters and CalMaster2s are listed in the left hand pane The details for the selected item are displayed in the right hand pane To edit a detail either double click the detail selected or click the button Type the new information and press Enter To open an alternate database...

Page 42: ...confirmed by the mains icon in the top right corner of the display C 4 The display shows the normal start up screen After a short time period with no activity this screen times out If at this stage the CalMaster 2 determines that a fast charge is necessary the display shows the text Fast Charging x xV otherwise the display switches off enters sleep mode immediately 5 If fast charging mode was enga...

Page 43: ...7 Registration IM VCM2 Issue 6 41 7 Registration In order to download fingerprint files to the CalMaster2 each flow meter must be registered To register 1 Open a web browser and type http www abbregister com in the address bar The ABB log in page appears ...

Page 44: ... press Next An e mail response is sent containing the Username and Password The registration for the selected product appears 3 Type the Serial number and Date of Purchase A confirmation appears 4 Click the link to view registration details Note If the date of purchase is not known use the date of installation ...

Page 45: ...ttp www abbregister com in the address bar The ABB log in page appears 2 Type the Username and Password and click Submit The registration details page appears 3 Click the Register another product link 4 Select the Product type from the drop down list and click Next The details page appears 5 Type the Serial Number and Date of Purchase Click Submit A confirmation page appears An e mail response is ...

Page 46: ...t file Fingerprint files are available for all registered flow meters To download fingerprint files the flow meter s must be registered with ABB see Section 7 page 41 To download fingerprint files 1 Open a web browser and type http www abbregister com in the address bar The ABB log in page appears 2 Type the Username and Password and click Submit The options page appears 3 Click View current regis...

Page 47: ... Click the link for the required flow meter A File Download dialog box appears 5 Click Save A file browser appears prompting for a location for the download Browse to C Program Files CalMaster2 Factory Files Fingerprints 6 Click Save 7 Install the fingerprint file see Section 5 6 page 34 ...

Page 48: ...onnect the CalMaster2 to the PC see section 4 2 page 22 2 From the Windows Start menu select Run 3 Type C Program Files ABB CalMaster2 Clock exe or click Browse to locate the file The utility appears 4 Select the COM port that the CalMaster2 is connected to 5 Click the Get CalMaster Time button or press F5 6 Click the Get CalMaster Date button or press F6 7 Click the Sync with PC Time button or pr...

Page 49: ...Field and Software Tools CalMaster2 and CheckMaster Notes IM VCM2 Issue 6 47 Notes ...

Page 50: ...Field and Software Tools CalMaster2 and CheckMaster Notes 48 IM VCM2 Issue 6 ...

Page 51: ...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 52: ...inuous product improvement and the right is reserved to modify the information contained herein without notice Printed in UK 10 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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