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ABB ProcessMaster User Manual

ABB ProcessMaster
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Safety
CI/FEX300/FEX500-EN FEX300, FEX500 EN - 5
1 Safety
1.1 General information and notes for the reader
You must read these instructions carefully prior to installing and commissioning the device.
These instructions are an important part of the product and must be kept for future reference.
These instructions are intended as an overview and do not contain detailed information on all
designs for this product or every possible aspect of installation, operation and maintenance.
For additional information or if specific problems occur that are not discussed in these
instructions, contact the manufacturer.
The content of these instructions is neither part of any previous or existing agreement, promise
or legal relationship nor is it intended to change the same.
This product is built based on state-of-the-art technology and is operationally safe. It has been
tested and left the factory in perfect working order from a safety perspective. The information in
the manual must be observed and followed in order to maintain this state throughout the period
of operation.
Modifications and repairs to the product may only be performed if expressly permitted by these
instructions.
Only by observing all of the safety instructions and all safety/warning symbols in these
instructions can optimum protection of both personnel and the environment, as well as safe and
fault-free operation of the device, be ensured.
Information and symbols directly on the product must be observed. They may not be removed
and must be fully legible at all times.
Important (Note)
For a list of all additional documents associated with the product, see section 9.1, "Other
appli
cable documents".
Important (Note)
An additional document with Ex safety instructions is available for measuring systems that
are used in explosion hazardous areas.
Ex safety information is an integral part of this manual. As a result, it is crucial that the
installation guidelines and connection values it lists are also observed.
The icon on the name plate indicates the following:

Table of Contents

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ABB ProcessMaster Specifications

General IconGeneral
TypeElectromagnetic Flowmeter
Liner MaterialPTFE, PFA, Polyurethane, Rubber
Electrode MaterialStainless steel, Hastelloy, Tantalum, Titanium, Platinum
Process ConnectionFlange, Wafer
Fluid Temperature-40 to 180 °C (-40 to 356 °F) Depending on liner
Output4-20 mA, HART, PROFIBUS PA, FOUNDATION Fieldbus
Power Supply100 to 230 V AC, 24 V AC/DC
Protection ClassIP67
ApprovalsATEX, IECEx, FM, CSA

Summary

Safety

General information and notes for the reader

Provides essential safety information and notes for careful reading of the manual.

Intended use

Defines the approved applications and operational purposes of the device.

Improper use

Details actions that constitute improper use, highlighting potential risks.

Target groups and qualifications

Specifies required qualifications for personnel involved in installation and operation.

Plates and symbols

Details safety, warning, and note symbols and their meanings.

Transport safety information

Provides critical safety guidelines to be followed during device transport.

Installation safety information

Outlines essential safety precautions and requirements for device installation.

Safety instructions for electrical installation

Details mandatory safety procedures for electrical connections and installation work.

Safety instructions for operation

Specifies safety rules and warnings crucial for the safe operation of the device.

Technical limit values

Lists the operational and technical limits that must be adhered to for safe use.

Allowed Fluids

Identifies the specific types of fluids approved for measurement with this device.

Returning devices

Provides instructions and procedures for returning the device for service or repair.

Disposal

Offers guidance on product disposal and compliance with WEEE and RoHS directives.

Device designs

Model with compact design

Describes the integrated transmitter and sensor design for compact models.

Model with remount mount design

Details the remote mount design with separate transmitter and sensor connected via cable.

Transport

Inspection

Instructs users to inspect devices for any damage that may have occurred during transit.

Transport of flanged units smaller than DN 450

Provides safe handling and lifting guidance for transporting smaller flanged units.

Transport of flanged units larger than DN 400

Details safe handling and transport methods for larger flanged units.

Mounting

General information on installation

Provides general guidelines and critical points to observe during the installation process.

Supports for meter sizes larger than DN 400

Offers guidance on proper support for larger meter sizes to prevent housing damage.

Mounting the measuring tube

Step-by-step instructions for the correct installation of the measuring tube.

Torque information

Specifies the correct tightening torque values for various flange connections.

ProcessMaster in flange design and HygienicMaster in flange or wafer-type design

Provides tightening torque values for flange connections for ProcessMaster and HygienicMaster.

Variable process connections HygienicMaster

Lists tightening torque values specific to variable process connections on HygienicMaster.

Information on EHEDG conformity

Details EHEDG conformity requirements and associated warnings for hygienic installations.

Information on 3A conformity

Provides information and installation requirements for achieving 3A conformity.

Installation Requirements

Outlines critical requirements for optimal device installation and performance.

Flow direction

Specifies the correct flow direction for installation to ensure accurate measurement.

Electrode axis

Guidance on the proper horizontal positioning of the electrode axis for accurate readings.

In- and outlet pipe sections

Details requirements for inlet and outlet pipe sections to ensure proper flow profiling.

Vertical connections

Provides instructions for vertical installation, particularly for abrasive fluids.

Horizontal connections

Details horizontal installation steps, emphasizing maintaining a full meter tube.

Free inlet or outlet

Recommendations to prevent air pockets and ensure a consistently full meter tube.

Strongly contaminated fluids

Advises on using bypass connections for handling strongly contaminated fluids.

Installation in the vicinity of pumps

Offers guidance on mitigating vibration effects when installing near pumps.

Installing the high temperature design

Provides instructions for installing the high temperature design with thermal insulation.

Devices with extended diagnostic functions

Notes on specific installation conditions required for devices with advanced diagnostics.

Installation in pipelines with larger nominal diameters

Guidance for installing in larger diameter pipelines, including pressure loss calculations.

Ground

Provides essential information and procedures for grounding the device correctly.

General information on ground connections

Outlines general principles and important considerations for device grounding.

Metal pipe with fixed flanges

Details the grounding process for metal pipes with fixed flanges.

Metal pipe with loose flanges

Describes the grounding procedure for metal pipes utilizing loose flanges.

Plastic pipes, non-metallic pipes or pipes with insulating liner

Provides grounding instructions for plastic, non-metallic, or lined pipes.

Sensor type HygienicMaster

Specific grounding instructions for the HygienicMaster sensor type.

Ground for devices with protective plates

Explains the function of protective plates for grounding and protection.

Ground with conductive PTFE grounding plate

Describes the grounding method using conductive PTFE grounding plates.

Electrical connections

Routing the signal and magnet coil cable

Guidance on routing signal and coil cables, including shielding and distance considerations.

Preparing the signal and magnet coil cable in the case of transmitters with dual-compartment housing

Instructions for preparing signal and magnet coil cables for dual-compartment transmitters.

Cable with part number D173D027U01

Steps for preparing the D173D027U01 cable for dual-compartment transmitter connections.

Cable with part number D173D031U01

Steps for preparing the D173D031U01 cable for dual-compartment transmitter connections.

Preparing the signal and magnet coil cable in the case of transmitters with single-compartment housing

Instructions for preparing signal and magnet coil cables for single-compartment transmitters.

Cable with part number D173D027U01

Steps for preparing the D173D027U01 cable for single-compartment transmitter connections.

Cable with part number D173D031U01

Steps for preparing the D173D031U01 cable for single-compartment transmitter connections.

Connecting the transmitter

Details on connecting the transmitter, including power supply and wiring.

Connecting the power supply

Instructions for connecting the power supply, including breaker and wiring requirements.

Transmitter with dual-compartment housing

Shows power supply terminal locations for dual-compartment transmitter housings.

Transmitter with single-compartment housing

Shows power supply terminal locations for single-compartment transmitter housings.

Connecting the signal and magnet coil cables

Explains how to connect signal and magnet coil cables to transmitter housings.

Connecting the flowmeter sensor

Provides instructions for connecting the flowmeter sensor to the transmitter.

Metal terminal box in the case of ProcessMaster and HygienicMaster

Instructions for connecting the sensor via a metal terminal box.

Plastic terminal box in the case of ProcessMaster

Instructions for connecting the sensor via a plastic terminal box.

Connection via cable conduit

Guidance on connecting via cable conduit and preventing moisture ingress.

Protection class IP 68

Details IP 68 protection class and connection requirements for submersion.

Sealing the connection box

Procedure for sealing the connection box using a sealing compound.

Terminal connection diagrams

Illustrates terminal connections for various communication protocols and peripherals.

Devices with HART protocol

Terminal connection diagrams specific to devices using the HART protocol.

Devices with PROFIBUS PA or FOUNDATION fieldbus

Terminal connection diagrams for PROFIBUS PA and FOUNDATION fieldbus devices.

Connection examples for the peripherals

Illustrates connection examples for peripherals with current and digital outputs.

Commissioning

Preliminary checks prior to start-up

Lists essential checks to perform before initiating the commissioning process.

Operation

Describes device operation using the LCD display and capacitive control buttons.

Menu navigation

Explains how to navigate through the device's menu system using control buttons.

Control button functions

Details the specific functions assigned to each control button for menu interaction.

Menu levels

Describes the device's menu structure: Process display, Information, and Configuration levels.

Process display

Explains the process display, showing current values and relevant symbols.

Description of symbols

Details the various symbols displayed and their respective meanings.

Error messages on the LCD display

Explains the format, classification, and meaning of LCD error messages.

Invoking the error description

Describes how to access detailed error descriptions from the information level.

Configuring the current output

Details on configuring the current output mode (active/passive) based on device type.

Transmitter with dual-compartment housing

Configuration of output settings for dual-compartment transmitters using jumpers.

Transmitter with single-compartment housing

Configuration of output settings for single-compartment transmitters using jumpers.

Commissioning the unit

Guides through the essential steps for commissioning the flowmeter unit.

Downloading the system data

Procedure for downloading system data, calibration, and transmitter settings.

Error message 'Incompatible sensor'

Troubleshooting steps for resolving 'Incompatible sensor' error messages during setup.

Parameterizing via the 'Easy Set-up' menu function

Guide to using the 'Easy Set-up' menu for quick and efficient device configuration.

Parameter overview

Easy Setup

Overview of parameters accessible through the 'Easy Setup' menu for quick configuration.

Device Info

Details on device information, sensor parameters, calibration data, and properties.

Device Setup

Covers device setup parameters like analog range, transmitter settings, and access control.

Sensor

Parameters related to sensor configuration, including Qmax, span, and location tags.

Transmitter

Parameters for transmitter configuration, units, and low flow cut-off settings.

Display

Parameters for display settings, including language, contrast, and operator page configuration.

Input / Output

Configuration of digital outputs, alarm settings, and signal types for inputs/outputs.

Pulse Setup

Settings for pulse output modes, pulses per unit, pulse width, and frequency.

Digital Input Setup

Configuration options for digital inputs, such as totalizer reset and alarm signals.

Current Output

Parameters for setting current output modes, alarm thresholds, and output behavior.

Process Alarm

Configuration of process alarms, including masking, simulation, and history.

Communication

Settings for communication protocols like HART and PROFIBUS PA, including device address.

Diagnostics

Overview of diagnostic functions, including detectors, measurements, and grounding checks.

Diagnosis Control

Controls for diagnostic functions, such as Empty Pipe Detector and Sensor Measurements.

Totalizer

Settings for totalizers, batching, and editing volume totals.

Extended diagnostic functions

General remarks

General notes on extended diagnostic functions, their availability, and initial activation.

Detection of partial filling

Detects partially filled flowmeter sensors and outputs an alarm via digital output.

Detection of gas bubbles

Detects gas bubbles in fluid, triggering an alarm based on adjustable limit values.

Electrode coating detection

Detects electrode coatings by monitoring limit values and triggers an alarm.

Conductivity monitoring

Monitors fluid conductivity against set limits, triggering alarms as needed.

Electrode impedance monitoring

Monitors electrode impedance to detect shorts or leakage, triggering alarms.

Sensor measurements

Includes monitoring of sensor temperature and coil resistance for diagnostics.

Sensor temperature monitoring

Monitors the temperature of the flowmeter sensor coils using adjustable limit values.

Monitoring of the sensor coil resistance

Monitors the resistance of the flowmeter sensor's coils against adjustable limits.

Trend

Stores measured values cyclically for trend analysis using internal memory.

Fingerprint

Compares current recorded values with factory calibration or commissioning values.

Checking the grounding

Function to perform an electrical grounding check on the device.

Performing the grounding check

Step-by-step guide to perform the grounding check and interpret the power spectrum results.

Recommended settings for diagnostic limit values

Provides recommended limit values for various diagnostic parameters for initial setup.

Limit values for the coil resistance

Recommended limit values for monitoring coil resistance based on fluid temperature.

Limit values for the electrode deposits

Recommended limit values for detecting electrode deposits based on QE values.

Limit values for the electrode impedance

Recommended limit values for monitoring electrode impedance based on average impedance.

Recommended settings for the Trend Logger

Recommended settings for the Trend Logger, specifically the logtime interval.

Appendix

Other applicable documents

Lists other relevant documents, datasheets, and interface descriptions for the product.

Approvals and certifications

Details the CE mark, explosion protection standards, and other relevant approvals.

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