ABB AquaMaster Explorer Installation guide

Brand: ABB

Model: AquaMaster Explorer

Category: Measuring, testing & control

Type: Installation guide

ABB AquaMaster Explorer is an electronic commercial water meter powered by an external battery pack. It is a high-performance electromagnetic flowmeter designed to measure the flow of electrically conductive fluids. The AquaMaster Explorer is suitable for use in a wide range of applications, including water distribution, wastewater treatment, and industrial process control.

Electronic Commercial Water Meter

AquaMaster

Explorer

Installation Manual

IM/AM/E_5

ABB

EN ISO 9001:2000

Cert. No. Q5907

The Company

We are an established world force in the design and manufacture of

instrumentation for industrial process control, flow measurement, gas and liquid

analysis and environmental applications.

As a part of ABB, a world leader in process automation technology, we offer

customers application expertise, service and support worldwide.

We are 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.

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.

EN 29001 (ISO 9001)

Lenno, Italy – Cert. No. 9/90A

Electrical Safety

This equipment complies with the requirements of CEI/IEC 61010-1:2001-2 "Safety requirements for electrical equipment for

measurement, control, and laboratory use". If the equipment is used in a manner NOT specified by the Company, 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 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 Communications 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 protected

through double insulation

Stonehouse, UK

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 and in

accordance with the information given.

4. Normal safety precautions must be taken to avoid the possibility of an accident occurring when operating in conditions

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 and spares

information.

0255

CONTENTS

AquaMaster

is a range of high performance

electromagnetic flowmeters for the measurement

of electrically conductive fluids and are normally

supplied as factory configured, calibrated

systems.

Warning.

• Installation and maintenance must

be carried out only by suitably trained

personnel.

• Read all relevant sections of this

manual before selecting a location.

• The safety requirements of this

equipment, any associated

equipment and the local environment

must be taken into consideration

during installation.

• Install and use this equipment in

accordance with relevant national

and local standards.

• Specific safety precautions apply to

the use of the GSM engine which

forms part of the GSM-equipped

version of this product. If the unit

purchased has GSM-capability, read

Appendix A on page 24 before

selecting a location.

1 INTRODUCTION

1 INTRODUCTION ......................................... 1

2 MECHANICAL INSTALLATION .................. 2

2.1 Unpacking .......................................... 2

2.2 Installation Conditions ........................ 2

2.3 Transmitter Dimensions ...................... 4

2.4 GSM-equipped Transmitters .............. 5

2.4.1 GSM Antenna Installation ....... 5

2.4.2 Connecting a Remote

Antenna ................................. 7

2.4.3 Installing a SIM Card .............. 8

3 ELECTRICAL INSTALLATION .................... 9

3.1 Bonding/Grounding ............................ 9

3.2 Connections ..................................... 14

3.2.1 Sensor Terminal Box

Connections (Remote Versions

only) ..................................... 14

3.2.2 Environmental Protection...... 14

3.2.3 Transmitter Connections ............... 17

3.3.1 Frequency Outputs ............... 17

3.3.2 Alarm Interface ..................... 17

3.3.3 Connector Input/Output

Connections ........................ 18

3.3.4 Local Computer Connection 19

3.3.5 Pressure Transducer ............. 20

4START-UP AND OPERATION .................. 21

4.1 Start-up ............................................ 21

4.2 Display Activation ............................. 22

4.3 Battery Replacement ........................ 22

4.4 Accessories/Spares Kits ................... 23

SPECIFICATION ............................................. 24

APPENDIX A – GSM-EQUIPPED UNITS –

SAFETY PRECAUTIONS ............................... 26

Safety Precautions .................................... 26

NOTES ............................................................ 27

Allow room to

read display

>2 x pipe dia.

minimum

>5 x pipe dia.

minimum

Flow Direction

60C (140F)

Maximum

–20C (–4F)

Minimum

AquaMaster

2 MECHANICAL INSTALLATION

2.1 Unpacking

2.2 Installation Conditions – Figs. 2.1 to 2.17

Caution. Do NOT exceed the maximum

working pressure marked on the

equipment.

Fig. 2.1 Unpacking

Fig. 2.2 Spillage

Fig. 2.3 Vibration

Fig. 2.4 Localized Heat

Fig. 2.5 Siting

Fig. 2.6 Straight Pipe Requirements

Fig. 2.7 Fluid Level

Fig. 2.8 Within Temperature Limits

Fig. 2.9 Shade

Supports

< 2m

(78in)

IP68 (NEMA 6P/

ENCLOSURE 6P)

Submerged

9 Months

Accrued Time

Backfill

(Recommended)

Adequate

Protection

Plate

80C (176F)

Maximum

–10C (14F)

Minimum

Fit gaskets

Gasket same

size as pipe

0.7m (2.3 ft)

minimum

For access to batteries, display

and communication connector.

2 MECHANICAL INSTALLATION…

Fig. 2.10 Above Ground

Fig. 2.11 Temperature Difference

Fig. 2.12 Within Environmental Rating

Fig. 2.13 Underground

Fig. 2.14 Cable Routing

Fig. 2.15 Gasket Fitting

Fig. 2.16 Separation of Sensors

Fig. 2.17 Access to Transmitter

AquaMaster

168

(6.6)

(2.0)

115

(4.5)

177

(7.0)

Ø6.5

(0.3)

Ø13

(0.5)

136

(5.4)

(0.8)

…2 MECHANICAL INSTALLATION

2.3 Transmitter Dimensions – Fig. 2.18 and 2.19

Fig. 2.18 Transmitter Dimensions

Fig. 2.19 Battery Pack Dimensions

135

(5.3)

135

(5.3)

(0.3)

(2.75)

Dimensions in mm (in.)

50mm

Remote

Antenna

Integral

Antenna

2 MECHANICAL INSTALLATION…

2.4 GSM-equipped Transmitters

2.4.1 GSM Antenna Installation – Figs. 2.20 and 2.21

Before deciding on an antenna mounting location, check that the local signal strength for the chosen

mobile phone network is satisfactory. Use the GSM-equipped transmitter's integral signal strength test

facility to establish signal strength. Refer to 'Commissioning test for signal strength' in the Quick

Reference Guide for the AquaMaster S with GSM (IM/AMG–QRG).

If a GSM-equipped transmitter is not available, a standard mobile phone on the same network, positioned

as close as possible to the intended location, will give a good indication of local signal strength. For GSM

and logger download services, a minimum of two visible signal strength indicator 'bars' are

recommended. For SMS text, a minimum of one 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 ground level

– the antenna is mounted 50mm below the chamber cover, which must be plastic – see Fig. 2.20

• Ensure the antenna will not become submerged under water – see Fig. 2.20.

• Metallic enclosures will seriously degrade the signal. If an enclosure is used it must be non-

metallic.

• Do not mount the antenna closer than 50mm to any solid wall or surface – see Fig 2.21.

• Do not mount the antenna beneath a solid surface (e.g. metal cover, floor/ceiling, etc).

Fig. 2.20 GSM Antenna Installation

 50mm

(2 in.)

Fig. 2.21 GSM Antenna Installation

…2 MECHANICAL INSTALLATION

…2.4.1 GSM-equipped Transmitters

AquaMaster

Remove the cover from the socket on

top of the transmitter.

Gently push the antenna plug into the

socket, then twist the screw ring clockwise

until locked.

2 MECHANICAL INSTALLATION…

2.4.2 Connecting a Remote Antenna – Fig. 2.22

Fig. 2.22 Connecting a Remote Antenna

…2 MECHANICAL INSTALLATION

Remove the transmitter from its mounting point.

Use water to wash off any loose dirt from the case.

On the back of the transmitter, unscrew and remove

the cover to the SIM card holder.

Carefully lift the right-hand edge

of the holder outwards.

Slide the SIM card into the carrier,

contact side down and bevelled

edge to the top-right.

Close the holder until it clicks into

place and refit the cover.

Fig. 2.23 Installing a SIM Card

…2.4 GSM-equipped Transmitters

2.4.3 Installing a SIM Card – Fig. 2.23

3.1 Bonding/Grounding – Figs. 3.1 to 3.9

Caution. For safety reasons and optimum performance, the flowmeter, pipelines and medium

must be correctly bonded and grounded according to regulations.

Notes.

• The flow sensor must not be connected to a ground spike.

• For bonding connections use 4mm

(<10AWG) cable.

• Sensors 80mm do not require grounding rings.

• Connect the transmitter ground connection to the flowmeter body ground – see Figs 3.6 and

3.7.

Fig. 3.1 All Metal Pipe, Including Lined Metal Pipe.

Fluid Contact Rings

See Figs. 3.6 and 3.7

Key for Figs. 3.1 to 3.9

Metal Pipes

Plastic Pipes

Fluid Contact Rings

See Figs. 3.6 and 3.7

Insulation

Fig. 3.2 Metal Pipe With Flange Adaptor

3 ELECTRICAL INSTALLATION

Fluid Contact Rings

See Figs. 3.6 and 3.7

Fluid Contact Rings

See Figs. 3.6 and 3.7

Fluid Contact Rings

See Figs. 3.6 and 3.7

Fig. 3.3 Flanged Metal Pipe to Plastic Pipe

Fig. 3.5 All Plastic Pipe

…3 ELECTRICAL INSTALLATION

Fig. 3.4 Metal Pipe With Plastic Make-Up Insert

3 ELECTRICAL INSTALLATION…

Fig. 3.6 Battery Powered Transmitter Mounted in a Chamber

Fig. 3.7 Mains or Battery Powered Transmitter in Roadside Cabinet with Local Ground

Fluid Contact Rings

Insulating Sleeve

and Washer

(not supplied)

Insulated connecting wire

(not supplied). Must be

adequately rated to carry

cathodic currents.

Gasket

Bonding Cable

(supplied)

Fluid Contact

Ring

Bonding Cables

(supplied)

…3 ELECTRICAL INSTALLATION

Caution. Do NOT

ground Cathodically

Protected Systems.

Fig. 3.8 Pipelines With Cathodic Protection, DN100mm

Insulating Sleeve

and Washer

(not supplied)

Insulated connecting wire

(not supplied). Must be

adequately rated to carry

cathodic currents.

Gasket

Bonding Cable

(supplied)

3 ELECTRICAL INSTALLATION…

Fig. 3.9 Pipelines With Cathodic Protection, DN 40mm to 80mm

Caution. Do NOT

ground Cathodically

Protected Systems.

3.2 Connections

3.2.1 Sensor Terminal Box Connections (Remote Versions only) – Fig. 3.10

Caution. (Remote versions)

• Remove foil screens completely, and plastic/foil screens and any fillers

• Twist the three screen wires together and sleeve them.

• Keep cable pairs twisted.

• Make connections only as shown.

• Maintain Environmental Protection at all times.

• Conduit connections must provide cable entry sealing.

…3 ELECTRICAL INSTALLATION

3.2.2 Environmental Protection – Fig 3.11

Warning.

• Potting materials are toxic – use suitable

safety 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

ELECTRICAL INSTALLATION.

• Do not overfill or allow the potting material to

come into contact with ‘O’ rings or grooves.

• Do not let potting material enter conduit, if

used.

Fig. 3.11 Potting the Terminal Box

Fig. 3.10 Sensor Terminal Box Connections (Remote Version)

CABLE

ABB

Violet

Blue

Green (Sleeved Ground)

Yellow

Orange

Red

Brown

Maximum Cable Lengths

STT 4000 Series:  80 m

STT 4005 Series:  250 m

Belden 8777:  80 m

Belden 8777

White

Black

Sleeved Ground

Red

Black

Green

Black

Caution. With Belden Cable 8777, ensure that the black wires are

not interchanged and remain with the associated pair.

3 ELECTRICAL INSTALLATION…

Fig. 3.12 Transmitter Connections

External

Battery

Pack

Outputs

(Pulses,

Alarm,

Scanreader)

Pressure

Transducer

(Optional)

Sensor

Local

Comms.

Remove the screwed cap on the sensor connector.

Gently push the sensor plug into the socket and rotate it until it engages;

then tighten the locking ring.

Note: If the sensor cable is fitted with the metal MIL-spec connector, then

connection is via the MIL-spec sensor cable adapter (part number

WEBC2001, available separately).

Note: If the sensor cable is terminated with flying leads, connection is via

a sensor cable adapter box (part number WABC2024/B, available separately).

Fig. 3.13 Sensor Connection

3.2.3 Transmitter Connections – Fig 3.12 to 3.14

…3 ELECTRICAL INSTALLATION

Fig. 3.14 Use of Tamper-Detection Seals

2 3

Slide the optional locking-ring (from pack WEBC 2004) over the

cable to be sealed.

Connect the cable to the appropriate transmitter connector.

Slide the locking-ring over the connector.

Pass the wire of the seal through both the hole in the locking-ring

and the matching hole in the front of the transmitter. Close the seal.

3.3 Input/Output Connections

Caution.

• Refer to SPECIFICATION for Input/Output ratings.

• Inductive loads must be suppressed or clamped to limit voltage swings

• Operation of outputs is programmable – see Quick Reference Programming Guide for

details.

• External isolators are not normally required as the pulse and alarm circuit is electrically

separated from all other AquaMaster connections.

• Capacitive loads must be inrush current limited.

• Fully-floating pulse outputs may be subject to static damage, e.g. connecting to a floating

datalogger, unless 'COM' is operated within its galvanic isolation range (35V) from earth.

3.3.1 Frequency Outputs – Fig. 3.15

3 ELECTRICAL INSTALLATION…

Fig. 3.15 Frequency Output Connections

Fig. 3.16 Alarm Output Connections

Note. Outputs 1 & 2 are not polarity sensitive. The common connection for these

outputs is designated ‘COM’.

Note. Output 3 is not polarity sensitive. The common connection for these outputs

is designated ‘COM’. Alarm functions are available only with product software

versions:  1.1 (Release 1)  2.1 (release 2). See Programming Guide to determine

software version.

Tel emetry, Electronic

Counters etc.

Counter/Totalizers

Forward Flow

and/or

Reverse Flow

I/P0V*

COM

O/P1

O/P2

PLC or Datalogger

COM

O/P1

O/P2

Common

Input 1

Input 2

COM

O/P3

Common

Alarm Input

3.3.2 Alarm Interface – Fig. 3.16

…3 ELECTRICAL INSTALLATION

3.3.3 Connector Input/Output Connections – Fig. 3.17

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Pin View

Fig. 3.17 Connector Input/Output Connections

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ABB AquaMaster Explorer Installation guide

Brand: ABB

Model: AquaMaster Explorer

Category: Measuring, testing & control

Type: Installation guide

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ABB AquaMaster Explorer Installation guide

ABB AquaMaster Explorer Installation guide

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