ABB MagMaster - Flow Meter & End to End Testing Procedure

ABB MagMaster™ – Flow Meter & ETE Testing Procedure

5/09/2016 - VER.01.01 XXX_DLIST_MEFLWMETR_ABB

ABB MagMaster™

Flow Meter & End to End Testing

Procedure

Created by

David List

On behalf of XXX

August, 2016

Employed by Ventia


5/09/2016 - VER.01.01 XXX_DLIST_MEFLWMETR_ABB

Objective

The aim of this procedure is to correctly verify the assigned MagMaster flow tube,

transmitter and end to end scaling:

Contents

Overview ............................................................................................................................................ - 1 -

Electromagnetic Flow Meter Principles ......................................................................................... - 2 -

Excitation Coils ............................................................................................................................. - 2 -

Sensing Electrodes ...................................................................................................................... - 3 -

Solution Ground ............................................................................................................................ - 3 -

Before You Begin ............................................................................................................................. - 4 -

1. Flow Sensor ID ..................................................................................................................... - 5 -

2. Flow Range ........................................................................................................................... - 6 -

3. Low Flow Cut Off .................................................................................................................. - 6 -

4. Clear SCADA Scaling .......................................................................................................... - 7 -

5. Loop Calibrator SCALING Test .......................................................................................... - 8 -

6. Flow Tube COIL Resistance Test ...................................................................................... - 9 -

7. Flow Tube COIL Insulation Resistance Test .................................................................... - 9 -

8. Flow Tube SCREEN Insulation Resistance Test .......................................................... - 10 -

9. Flow Tube ELECTRODE Resistance Test ..................................................................... - 11 -

10. Flow Tube ELECTRODE Screen Test ........................................................................ - 12 -

11. ELECTRODE Induced Voltage Test ........................................................................... - 13 -

12. FINAL Scaling Test ........................................................................................................ - 13 -

Tips… ............................................................................................................................................... - 15 -

Transmitter Verification ............................................................................................................. - 15 -

Transmitter Configuration ......................................................................................................... - 15 -

ABB CalMaster™ ....................................................................................................................... - 16 -

References ...................................................................................................................................... - 16 -

Contact ABB .................................................................................................................................... - 17 -

Enquiries .......................................................................................................................................... - 17 -


- 1 - 5/09/2016 - VER.01.01 XXX_DLIST_MEFLWMETR_ABB

Overview The MagMaster™ is an electromagnetic flow meter that was released in the early

90’s by ABB Kent-Taylor. It was widely adopted by many industries including water

and sewer. The MagMaster™ is an integral part of the many water networks and

continues to be used and maintained. The MagMaster™ is well documented and

offers many of the same features that modern flow meters are correctly supporting.

This document will attempt to run through these features and how to best test/verify

the MagMaster™ transmitter and flow tube, seen below;

The procedure will also include the most effective way to verify scaling from the field

to Clear SCADA.

Each step is in chronological order and is designed to easily flow through the

verification process. With each step adding to the understanding of the next.

The tester will be asked to complete a verification document designed to match this

procedure.

Please find the “Ventia - Flow Meter Report - TEMPLATE” document attached to this

PDF.

TRANSMITTER FLOW TUBE



Electromagnetic Flow Meter Principles According to Faraday’s Law, an electrical conductor moving through a magnetic field

produces an electric signal within the conductor. In the case of “MagMeters”, the

liquid is the conductor and electromagnetic coils surrounding the flow tube generate

the magnetic field. Two electrodes embedded on opposite sides of the flow tube pick

up the signal. The flow signal at the electrodes is directly proportional to the flow

velocity, the intensity of the magnetic field and the width of the pipe (distance

between electrodes).

The mag meter consists of three main elements:

The excitation coils

The sensing electrodes

The solution/process ground

Excitation Coils The coils in a flow tube are designed to create an electromagnetic field across the

diameter of the pipe. Most mag meters induce a pulsed DC current (approximately

500mA @ 5 – 8Hz) to the coils. This allow the resistance of the coils to drift (slightly)

over time.

The resistance of the coils will vary across different manufactures and models.

Manufactures will typically list an acceptable resistance range across the flow tube

coils.



Sensing Electrodes

The sensing electrodes a flow tube are typically made from stainless steel. The

electrodes are insulated via a protective liner that prevent short circuiting with the

flow tubes main body.

Over time these electrodes can calcify or corrode, offen referred to as “dirty”

electrodes. How dirty the electrodes are can affectively be measured using a moving

coil/analog multimeter.

Solution Ground

Often overlooked when installing and maintain mag meters is the solution ground.

The purpose of the solution ground is to provide a direct reference to the process

liquid. This ensures the same potential between the electrodes and process medium.

In case of non-metallic interconnections, grounding rings are required. Though often

the reference is an electrode that sits at the bottom of the flow tube. Certain tests

can be performed using the solution ground to check for unwanted (noisy) signal

voltages or cable insulation failure.

For more information on electromagnetic flow meters see the link below;

Endress+Hauser - Electromagnetic Flow Measuring Principle

https://www.youtube.com/watch?v=f949gpKdCI4



Before You Begin Before conducting the MagMaster™ verification you will need the following;

MagTran™

MagTran™ is a proprietary software created by ABB. This allows

the customer to interrogate MagMaster™ transmitter and extract

vital information about the flow meter – Please find MagTran™

attached to this PDF. NOTE this software is only compatible with

Windows XP.

Serial DB9 Cable

The cable required to connect to the MagMaster™ is a FEMALE

Serial DB9. The pin out and baud settings can be found in the

MagMaster™ manual, Appendix A, Page 11 – Please find the

MagMaster manual attached to this PDF.

mA Loop Calibrator & Digital Multimeter

For the purposes of this procedure we will be using the Fluke 789

Process Meter. This will be used to verify the End to End scaling

and test the flow tube coil resistance.

Analog Multimeter

An Analog Multimeter is required for this procedure. It will be used

to measure the resistance of the sensing probes. NOTE using a

digital multimeter can produce undesired results.

Insulation Resistance (IR) Tester

An IR tester is required for this procedure. It will be used to

measure to continuity of the flow tube jacket.

The above items are main testing equipment required to successfully complete this

procedure. NOTE It is assumed that the technician will also have general tools of the trade.

IMPORTANT

The following procedure should be undertaken by a “competent person”. It is assumed that

the tester has a basic understanding of electromagnetic flowmeter principals.

Without a proper understanding of why a certain step is being undertaken, the tester may

produce undesired results or even damage to the flow meter.



1. Flow Sensor ID

To find the flow meter ID, you must connect to the MagMaster™ using the

MagTran™ software. Please see the MagMaster™ manual to establish a connection to the

transmitter.

Once connected you will need to follow the prompts to the “Login” menu. Proceed

with the Level 2 password “engineer” see below;

Once logged in, return to the main menu. You should now be able to see the

extended menu. Proceed to the “Snsr” menu, see below;

NOTE: DO NOT attempt to change any “Snsr Fact” values. These values have been

matched to the flow tube. Changing them will offset any future readings.



2. Flow Range

Return to the main menu and proceed to the “Flow” menu, see below;

Here you can view and edit the “MAX” flow range.

The purposes of this document we will assume the flow range is 0 – 200 l/s.

3. Low Flow Cut Off

Whilst still in the “Flow” menu, proceed to “Flow Cutoff”.

Note: The low flow cut off is NOT the flow factor. It is the flow velocity in mm/s.



4. Clear SCADA Scaling

Once you have established the flow range you can now verify the Clear SCADA

scaling factor. NOTE in most cases this will be the same value as the flow range.

Login to Clear SCADA, proceed to the appropriate site mimic and find the associated

flow element (FE6056). Left click on the flow value and proceed to “Display Historic

Trend”.

A new window will appear featuring the flow trend of the past 24 hours. Along the “Y”

axis (to the left) will be the input scaling/range, see highlighted below;

This is the default scaling for the flow range. If this value does not equal the

MagMaster™ flow range, established in step 1. Then consult the YVW SCADA team

or appropriate administrator to have it corrected.



5. Loop Calibrator SCALING Test To verify that the Clear SCADA scaling is accurate you will need to perform a 5-point

check from the 4-20mA input to the MagMaster™ transmitter.

First remove power to the transmitter. Then identify the current loop and remove it

from the terminals. Proceed to “source” a mA signal from your loop calibrator, seen

below;

Proceed through a slow 5-point test. Starting from 4mA and finishing at 20mA. The

results should resemble 5 equally stepped intervals, seen below;

Note down these values for the verification report.

Once the scaling test is complete reconnect the current loop but DO NOT reconnect

power to the transmitter. The following steps require power to be disconnected from

the transmitter.



6. Flow Tube COIL Resistance Test

Before testing, remove the sensor wires from the terminals. Using a digital

multimeter, test the flow tubes coil resistance. Turn your multimeter to the OHM’s

setting and test between sensor wire “CD1” & “CD2”, seen below;

This result should be between 5 - 100Ω. Any value above or below this range is a

FAIL. A fail indicates that the coil is open or short circuit. This will mean replacing the

flow tube.

7. Flow Tube COIL Insulation Resistance Test

Using an insulation resistance tester (IR), test the coils resistance to earth. Turn your

IR tester to the 500V setting and place your earth (black) probe on the drain

(ground). Then with the red probe test “CD1” and “CD2”, seen below;

The results should be between 5 - 200MΩ. Anything below this is a FAIL. A fail

indicates that the coil is shorted circuited to earth. This will mean replacing the flow

tube.



8. Flow Tube SCREEN Insulation Resistance Test

STEP 1

Using an insulation resistance tester (IR), test the screen resistance to earth. Turn

your IR tester to the 500V setting and place your earth (black) probe on the signal

ground (SIG GND). Then with the red probe test “DS1” and “DS2”, seen below;

The results should be >200MΩ. Anything below this is a FAIL. A fail will indicate that

signal screens (DS2 & DS2) are in some way in contact with the process fluid. This

may not be imperative to the overall operation, though it may not provide the desired

flow value.

STEP 2

Following the above step, test the insulation resistance between each signal screen.

Turn your IR tester to the 500V setting and place your earth (black) probe on “DS1”

and the red probe on “DS2”, seen below;

The result should be >200MΩ. Anything below this is a FAIL. A fail will indicate that

signal screens (DS2 & DS2) are short circuited to each other. This may not be

imperative to the overall operation, though it may not provide the desired flow value.



9. Flow Tube ELECTRODE Resistance Test

STEP 1

Using an analog multimeter, test the electrode resistance to solution ground. Turn

the multimeter on, ensuring the resistance setting can go beyond 200KΩ. Place the

negative probe on the signal ground (SIG GND). Then with the positive probe test

“SIG1” and “SIG2”, seen below;

The results should be between 2 – 20KΩ. Anything below this is a FAIL. A fail will

indicate that electrodes are dirty or faulty. A different reading between “SIG1” and

“SIG2” will indicated that one electrode is dirtier than the other.

STEP 2

Using an analog multimeter, test the electrode resistance between each signal cable.

Turn the multimeter on, ensuring the resistance setting can go beyond 200KΩ. Place

the negative probe on “SIG1” and the positive probe on “SIG2”, seen below;

The result should be between 4 – 40KΩ. Anything below this is a FAIL. A fail will

indicate that electrodes are dirty or faulty. This reading should roughly be the

accumulated value of the previous step.

NOTE: some flow sensors manufactured in late 2000’s may have a 47k Ohm resistor in series with

the electrode (on the terminal board of the sensor). These were sometimes used in raw water flow

sensors >300mm, but are not common. The resistors can be shorted out if you think the readings are

too high.



10. Flow Tube ELECTRODE Screen Test

Using an analog multimeter, test for any leakage between signal wire and signal

screen. Turn the multimeter on, ensuring the resistance setting can go beyond

200KΩ. Place the negative probe on “DS1”. Then with the positive probe test “SIG1”.

Repeat this process for “DS2” & “SIG2”, seen below;

The result should be INFINITE. Anything below this is a FAIL. A fail will indicate that

electrode wire is leaking to the screen. This reading should roughly be the

accumulated value of the previous step. This may not be imperative to the overall

operation, though it may not provide the desired flow value.

STOP!

This concludes all testing that requires the flow sensor cable to be disconnected from the

transmitter. Before proceeding to the next step you must conduct the following;

The sensor wires should be momentarily shorted to ground to discharge any residual voltage

remaining on the signal screens as part of the IR testing phase. Re-connecting without doing

this step may damage the transmitter’s input circuitry.

Reconnect the sensor cable to the loom. Then turn the transmitter back ON.

Pro

ceed



11. ELECTRODE Induced Voltage Test

Using a digital multimeter, test for any induced voltages in the signal screens. Turn

your meter to VDC. Place the negative probe onto the “SIG GND”. then using the

positive probe test “DS1” & “DS2”, seen below;

The result should be < = +/- 0.5VDC. Anything above this is a FAIL. A fail will

indicate that there are external induced voltages present in the signal cable. This

may not be imperative to the overall operation, though it may not provide the desired

flow value.

12. FINAL Scaling Test

The final test is to ensure that mA output from the transmitter is correct. Knowing that

you have already confirmed the scaling in Step 5 Loop Calibrator SCALING Test,

any abnormal readings from this test can only be attributed to the transmitter output.

Please make sure the mA loop is connected before starting.

Begin by establishing a connection with the MagMaster™ transmitter and enter the

password as shown is Step 1 Flow Meter ID.

Once logged in, proceed to the TEST menu, seen below;

Set the transmitter into “Test Mode” and then proceed to manually in enter the flow

values equal to a 5-point test.



For the purposes of this document we will assume the range is 0-200 l/s. In this

instance the syntax would be as shown below;

As can be seen to the left, the input values increment over 5

points of the range.

Clear SCADA reflect a similar result to the loop calibrator test, seen below;

Record the results displayed in SCADA.

FINISH

All testing is now fully complete. Please publish the results in the report attached to

this PDF.



Tips…

Transmitter Verification

The following can tip can be used and simple transmitter verification tool. Though it

may not give a proper indication of the overall health of the transmitter, it will show if

there is major component fault.

With the transmitter switch ON. Use a spare piece of wire and short it between

“SIG1” & “SIG2”, shown below;

If the reading is 0.0, then the transmitter is OK.

PLEASE NOTE

This is NOT a true indication of transmitter functionality. If you have any concerns about

health of the transmitter, please Contact ABB.

Transmitter Configuration

Using the MagTran™ software you can save the current configuration file. This may

be useful if the transmitter memory is unable to be retrieved. You may also want

extract the FULL configuration data as text.

Both or one of these files can then be attached to the report PDF.



ABB CalMaster™

Whist the method of testing the ABB MagMaster™ in this document, will reveal most

failures. At the end of the testing you may not be fully satisfied with the results. The

final ETE test may have failed or the real time reading may not fully reflect what is

expected. This is why ABB developed the CalMaster™.

The CalMaster™ is a device that can plug into the MagMaster™ in situ. The

CalMaster™ performs a full validation and verification of the transmitter and flow

tube. The results are then published and delivered to the customer.

Although designed to be used in situ. If your confident with the flow tubes

performance, you can just send the transmitter to the ABB service team and they will

verify the transmitter against their own flow tube.

Please Contact ABB for more information.

References Please find the following files attached to this PDF;

Magtran V1-10.zip (MagMaster Programing Software)

Ventia - Flow Meter Report - TEMPLATE.pdf

Ventia - Flow Meter Report - FE6056 - EXAMPLE.pdf

ABB MagMaster User Manual.pdf

ABB CalMaster Data Sheet.pdf



Contact ABB Although the MagMaster™ is no longer available, it continues to be supported by the

ABB service team. The contact information is below;

Address: 601 Blackburn Road

Suburb: Notting Hill

State: Victoria

Service Ph: 1800 222 435 (1800-ABB-HELP)

Melbourne Service Dept. Direct Ph: +61 2 9738 2277

For further information see the ABB website: http://new.abb.com/au

Enquiries Should you need any clarification on this document please contact myself;

David List Mob: 0408 006 344 Email: [email protected]

http://new.abb.com/au

MagMaster Transmitter

CalMaster

User GuideIM/CALMAS Issue 3

ABBThe Company

We are an established world force in the design and manufacture ofinstrumentation for industrial process control, flow measurement, gasand liquid analysis and environmental applications.

As a part of ABB, a world leader in process automation technology, weoffer customers application expertise, service and support worldwide.

We are committed to teamwork, high quality manufacturing, advancedtechnology and unrivalled service and support.

The quality, accuracy and performance of the Company’s products resultfrom over 100 years experience, combined with a continuous program ofinnovative design and development to incorporate the latest technology.

The UKAS Calibration Laboratory (No. 0255) is just one of ten flowcalibration plants operated by the Company, and is indicative of ourdedication to quality and accuracy.

Health and Safety

To ensure that our products are safe and without risk to health, the following points must be noted:

1. The relevant sections of these instructions must be read carefully before proceeding.

2. Warning labels on containers and packages must be observed.

3. Installation, operation, maintenance and servicing must only be carried out by suitably trained personnel andin accordance with the information given.

4. Normal safety precautions must be taken to avoid the possibility of an accident occurring when operating inconditions of high pressure and/or temperature.

5. Chemicals must be stored away from heat, protected from temperature extremes and powders kept dry.Normal safe handling procedures must be used.

6. When disposing of chemicals ensure that no two chemicals are mixed.

Safety advice concerning the use of the equipment described in this manual or any relevant hazard data sheets(where applicable) may be obtained from the Company address on the back cover, together with servicing andspares information.

EN ISO 9001:2000

Cert. No. Q 05907

EN 29001 (ISO 9001)

Lenno, Italy – Cert. No. 9/90A

REGISTERE

D

Electrical Safety

This equipment complies with the requirements of CEI/IEC 61010-1:1993 "Safety requirements for electricalequipment for measurement, control, and laboratory use". If the equipment is used in a manner NOT specified by theCompany, the protection provided by the equipment may be impaired.

Symbols

One or more of the following symbols may appear on the equipment labelling:

Information in this manual is intended only to assist our customers in the efficient operation of our equipment. Use of thismanual for any other purpose is specifically prohibited and its contents are not to be reproduced in full or part withoutprior approval of the Technical Publications Department.

Warning – Refer to the manual for instructions

Caution – Risk of electric shock

Protective earth (ground) terminal

Earth (ground) terminal

Direct current supply only

Alternating current supply only

Both direct and alternating current supply

The equipment is protectedthrough double insulation

1

CONTENTS

Contents Page1 Preparation .......................................... 2

1.1 Unpacking ................................... 2

2 INSTALLATION ................................... 22.1 Adapting the MagMaster

Transmitter ................................. 22.2 Preparing the Transmitter for

Verification ................................. 32.2.1 Removing the Covers ..... 32.2.2 Fitting the Adaptor Board 42.2.3 Wiring the Adaptor Plug .. 52.2.4 System Setup ................. 5

3 OPERATION ........................................ 63.1 Software Installation ................... 6

3.1.1 Windows 3.1 or 3.11 ....... 63.1.2 Windows 95 .................... 6

3.2 Initialising the CalMaster ............ 63.3 Battery Charging ......................... 7

2

2.1 Adapting the MagMasterTransmitterTo enable a MagMaster system to be testedby the CalMaster it is necessary to initially fita small adaptor board to the MagMastertransmitter. This adaptor is provided with theCalMaster Unit.

Once the adaptor is fitted to the MagMastertransmitter, the CalMaster can be easilyconnected to the transmitter for testing at anytime.

Extra adaptor kits are available from theCompany

The adaptor is supplied in the form of a PCBfitted with connectors which fit into the sensorconnection terminals of the MagMastertransmitter.

A connection socket is also provided, whichafter termination with the sensor cable, isconnected with the plug on the adaptor PCB.This provides a flexible means of insertingconnecting leads from the CalMaster, whentesting is required, and reconnecting theMagMaster sensor wiring when the testing iscomplete.

1 PREPARATION 2 INSTALLATION

1.1 UnpackingUnpack and visually inspect the CalMaster.

Also packed with the CalMaster are:a) CalMaster sensor test lead set.

b) CalMaster to MagMaster communicationlead set (includes three test probes forfrequency measurement).

c) Adaptor PCBs incorporating a plug toaccept the socket in item d) below.

d) Socket which fits into item c) above.The socket is first terminated with thesensor cable.

e) One lead to interconnect the CalMasterand a computer (Serial Data Connection).

f) Screwdriver for terminals.

g) Two 'CalMaster Software' Disks.

h) This Instruction Manual.

i) Mains operated battery charger

j) Lead for charging battery from12 Volts.

Save packing materials for any re-shipment,or to support any claim of shipment damage.All damage claims are made against thecarrier and are the responsibility of thecustomer.

Fig. 2.1 Adaptor Board for Transmitter

Adaptor PCB fitted with plug,and connectors for directconnection to terminals

Plug

Socket for terminationof sensor cable

3

2.2 Preparing the MagMaster Transmitter for Verification2.2.1 Removing the Covers

2 INSTALLATION…

Fig. 2.2 Access to fit Adaptor Board

2

2...andSlide Off

1 SlideDown

4

SlackenCaptiveScrews

RemoveProtectionCover

3

Pull Out Slightly...

4

…2 INSTALLATION

2.2.2 Fitting the Adaptor Board(Fig. 2.3 and 2.4)a) Turn off the power to the MagMaster.

b) Record the position of the sensor cablewiring and remove the wiring from theterminals. Slacken the terminal screwsby at least 6 turns.

c) Carefully ease the sensor wiring to one

side and arrange the adaptor board sothat the extended pins fit into theterminals previously occupied by thesensor wiring – see Fig.2.4.

d) Fit and tighten the securing screw to thecorner of the adaptor board.

e) Tighten the associated terminal blockscrews.

Fig 2.3 Normal Sensor Wiring in the Transmitter

Fig 2.4 Fitting the Adaptor Board

DS

2

IC 2

CD

1

CD

2

SIG

GN

D

DS

1

SIG

1

Grey CoaxPink Inner (SIG 2)Screen (DS 2)

Red(CD 1)

Yellow(CD 2)

White CoaxBlue Inner (SIG 1)Screen (DS 1)

Ground Wire(Safety Earth)

Violet

AdaptorBoard

ALA

RM

1F

OU

T A

ALA

RM

2F

OU

T B

PLS

OV

PLS

OV

EX

T I/

P+

EX

T I/

P-

TX

- S

IGR

X-

SIG

TX

+ S

IGR

X+

SIG

OV

C

N

+

L

5

…2 INSTALLATION

2.2.3 Wiring the Adaptor Socket(Fig. 2.5)The wires in the sensor cable must now bewired to the 8-way adaptor socket which willthen connect to the plug on the adaptorboard.

1 Adjust the wire lengths of the sensorcable to allow for termination andsubsequent removal of the adaptorsocket.

2 Insert the sensor cable wiring into thesocket as shown in Fig 2.5, and tightenthe plug screws with the screwdriverprovided.

Caution. Ensure that no bare wires toucheach other; in particular, ensure thatthere is no connection between thescreens of the grey and white coaxialwires.

3 Insert the adaptor socket into the plug onthe adaptor PCB.

Warning. Testing the MagMasterinvolves operation with the MagMasterterminal cover removed, exposing liveterminals. Take precautions to avoidelectric shock hazard.

Switch on the power to the MagMaster andcheck that the system operates correctly.

If the MagMaster operates correctly, eitherthe transmitter covers can be replaced fornormal working or the MagMaster can betested by the CalMaster.

Fig 2.5 Fitting the Sensor Wiring onto the Adaptor Socket

Blue

CD

1C

D2

GR

OU

ND

3

2

RedYellow

PinkGrey

White

Caution. Remove any exposedblack conductive layer from theinner insulation of both coaxialcables

VioletGround Wire

1

DS

2

DS

1S

IG 1

SIG

GN

D

SIG

2

6

…2 INSTALLATION

2.2.4 System Setup (Fig. 2.6)

Warning. Care is needed when CalMaster isused with cathodically protectedMagMasters.Cathodically protected installations, wired asdirected in the MagMaster manual, whichisolate the sensor using earthing flanges, areelectrically earthed and do not pose anysafety issues.When apparatus, such as CalMaster or thePC, are connected to systems which 'float' thesensor at the cathodic potential, thisapparatus will also float at the cathodicpotential and therefore must not be groundedor accidentally grounded.

With the adaptor PCB installed in the MagMasterTransmitter as detailed in Section 2.2.2, and thesensor cable plugged into the adaptor as fornormal operation:

Fig. 2.6 Connection Details for Initialisation

MagMaster CalMaster

1 2 3 4

Sensor

SensorTest Lead Set

ASEA BROWN BOVERI

CalMaster

a) Connect lead 3 of the CalMaster to theMagMaster 9-pin D-Type socket. The threesmall probes should not be connected untilrequested to do so by the CalMaster software.For details of when to connect these probeleads, follow the instructions on the providedsoftware – see Section 3.2. For details ofwhere to connect the probe leads, follow the'on-line help' under the heading, 'test leadconnections'.

b) Connect the 9-Pin D-Type socket on theCalMaster to a computer (Serial CommsConnection).

Note. The use of CalMaster with a linepowered desktop PC, as opposed to aportable, battery powered PC, is notrecommended, as the resulting ground(eqrth) loop can corrupt the sensitiveCalMaster measurements.In these circumstances, an external RS232isolator between the PC and the CalMasterwill effect a solution

7

3 OPERATION

3.1 Software Installation

Note. The CalMaster Program can beused with or without a 'Mouse'. Whereinstructions say 'Select', either click onthe item with the left hand mouse button,or use the 'TAB' key to move betweenfields and press the 'ENTER' key tocomplete the selection.

Insert the first CalMaster floppy disk into thecomputer disk drive and proceed as follows:

3.1.1 Windows 3.1 or 3.11a) Select 'RUN' from the Program or File

Manager menu.

b) Type 'a:setup' or 'b:setup', depending onthe floppy drive designation.

c) Press 'ENTER' and follow instructions.

3.1.2 Windows 95a) Press 'START'

b) Select 'Settings', 'Control Panel' anddouble click on 'Add/Remove Programs'.

c) Choose 'Install' and follow the instructions.

3.2 Initialising the CalMaster

Note. It is advisable to avoid the use ofradio equipment in the vicinity of aCalMaster/MagMaster test setup, duringtesting.

a) From Windows 'Program Manager' open the'ABB Applications' folder and double clickon the 'CalMaster' icon. The programautomatically finds the MagMaster and opensup to the Main 'ABB' Screen.

d) Select 'Test Meter', and the 'VerificationInformation' screen is displayed.

c) Follow the on–screen instructions andon–screen Help as required – click on theHelp button or press F1.

3.3 Battery ChargingThe CalMaster internal battery may becharged using the mains charger unitsupplied, or from a 12 volt vehicle connectorfor which a lead is also supplied.

Charging is automatic and takesapproximately 4 hours for a dischargedbattery.

For further information, refer to <batterymonitoring> from the CalMaster <options>menu.

…3 OPERATION

8

NOTES

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We provide a comprehensive after sales service via ourWorldwide Service Organization. Contact one of thefollowing offices for details on your nearest Service andRepair Centre.

United KingdomABB LimitedTel: +44 (0)1453 826661Fax: +44 (0)1453 829671

United States of AmericaABB Inc.Tel: +1 215 674 6000Fax: +1 215 674 7183

Client WarrantyPrior to installation, the equipment referred to inthis manual must be stored in a clean, dryenvironment, in accordance with the Company'spublished specification.Periodic checks must be made on theequipment's condition. In the event of a failureunder warranty, the following documentationmust be provided as substantiation:

1. A listing evidencing process operation andalarm logs at time of failure.

2. Copies of all storage, installation, operatingand maintenance records relating to thealleged faulty unit.

The Company's policy is one of continuous productimprovement and the right is reserved to modify the

information contained herein without notice.

Printed in UK (08.09)

© ABB 2009

ABB Inc.125 E. County Line RoadWarminsterPA 18974USATel: +1 215 674 6000Fax: +1 215 674 7183

ABB has Sales & Customer Supportexpertise in over 100 countriesworldwide

www.abb.com

ABB LimitedOldends Lane, StonehouseGloucestershireGL10 3TAUKTel: +44 (0)1453 826661Fax: +44 (0)1453 829671

IM/C

ALM

AS

Issu

e 3

Ventia - Flow Meter Report

1

Before competing this report please refer to the appropriate and flow meter test manual.

Job Details

Customer

Work Order & Flow Element

Service Technician

Flow Meter Information

Manufacture

Model Number

Serial Number

Flow Meter Testing Steps

Step # PASS FAIL Value

1. Flow Sensor ID

2. Flow Range

3. Low Flow Cut Off


5. Loop Calibrator SCALINGTest

6. Flow Tube COILResistance Test


2

COMMENTS

Have you attached any supporting documentation to this report?

7. Flow Tube COIL InsulationResistance Test

8. Flow Tube SCREENInsulation Resistance Test

9. Flow Tube ELECTRODEResistance Test

10. Flow Tube ELECTRODEScreen Test

11. ELECTRODE InducedVoltage Test



3

Please sign below to acknowledge that you have conducted the test in accordance with the appropriate

testing procedure and all results are truthful:

SIGN

Above is a digital signature. If you don’t have one already saved, please follow the prompts to create a new one.

Once signed you must save the final document as a separate PDF.

THE DOCUMENT CAN NOT BE EDITED AFTER THE SIGNATURE IS CERTIFIED

Once you have completed this report please attach it to the appropriate work order.


1

Before competing this report please refer to the appropriate and flow meter test manual.

Job Details

Customer

Work Order & Flow Element

Service Technician

Flow Meter Information

Manufacture

Model Number

Serial Number

Flow Meter Testing Steps

Step # PASS FAIL Value

1. Flow Sensor ID

2. Flow Range

3. Low Flow Cut Off


5. Loop Calibrator SCALINGTest

6. Flow Tube COILResistance Test


2

COMMENTS

Have you attached any supporting documentation to this report?

7. Flow Tube COIL InsulationResistance Test

8. Flow Tube SCREENInsulation Resistance Test

9. Flow Tube ELECTRODEResistance Test

10. Flow Tube ELECTRODEScreen Test

11. ELECTRODE InducedVoltage Test



3

Please sign below to acknowledge that you have conducted the test in accordance with the appropriate

testing procedure and all results are truthful:

SIGN

Above is a digital signature. If you don’t have one already saved, please follow the prompts to create a new one.

Once signed you must save the final document as a separate PDF.

THE DOCUMENT CAN NOT BE EDITED AFTER THE SIGNATURE IS CERTIFIED

Once you have completed this report please attach it to the appropriate work order.

Printed Output From File "C:\PROGRA~1\ABBLIM~1\MAGTRAN\FE6056.MAG" Program v1.00 (18/02/2004) (WIN-PC) File Produced : 9/08/2016 9:07:09 AM ** Display Menu ** ------------------ Display Mode = 0 Display Resolution = 2 ** Flow Menu ** --------------- Flow Range = 200.00000 Flow Units = Ltr Flow Multiplier = x1 Flow Time = s Flow Response = 3 Flow Probe Ins = 1.00000 Flow Probe Prof = 1.00000 Flow Cutoff = 5 ** Analog Menu ** ----------------- Analog FSD = 20 Analog Zero = 4 Analog Dir Fwd = 1 Analog Dir Rev = 0 Analog No. 2 = 100.00000 ** Pulse Menu ** ---------------- Pulse Factor = 0.00099 Pulse Cutoff = 0 Pulse Max = 800 Pulse Idle = 1 Pulse Size = 100 ** Totaliser Menu ** -------------------- Totaliser Units = Ltr Totaliser Multiplier = k Totaliser Clear Enab = 0 ** Alarm No.1 Menu ** --------------------- Alarm No.1 Idle = 1 Alarm No.1 Enable = 1 Alarm No.1 Fault = 1 Alarm No.1 Forward = 0 Alarm No.1 Reverse = 0 Alarm No.1 Cutoff = 0 Alarm No.1 MtSensor = 1 Alarm No.1 Hi = 0 Alarm No.1 Lo = 0 Alarm No.1 Analog = 0

Alarm No.1 Pulse = 0 ** Alarm No.2 Menu ** --------------------- Alarm No.2 Idle = 1 Alarm No.2 Enable = 1 Alarm No.2 Fault = 0 Alarm No.2 Forward = 0 Alarm No.2 Reverse = 1 Alarm No.2 Cutoff = 0 Alarm No.2 MtSensor = 0 Alarm No.2 Hi = 0 Alarm No.2 Lo = 0 Alarm No.2 Analog = 0 Alarm No.2 Pulse = 0 ** Alarm Trip Menu ** --------------------- Alarm Trip Hi = 110 Alarm Trip Lo = -110 Alarm Trip Hyst = 1 Alarm Trip Disp = 0 ** Input Menu ** ---------------- Input Clr Input Idle = 0 ** MtSensor Menu ** ------------------- MtSensor Trip = 50 ** Sensor Menu ** ----------------- Sensor Number = V/35697/2/2 Sensor Tag = FE6056 Sensor Size = 450 Sensor FACTOR 1 = 1.36368 Sensor FACTOR 2 = 0 Sensor FACTOR 3 = 5 Sensor FACTOR 4 = 1.00000 <<== END OF FILE ==>>

Engineering

ABB MagMaster - Flow Meter & End to End Testing Procedure