Endres+Hauser Flowjack ZX 6000 Operating instructions

Flowjack ZX 6000

Flow simulation

system

Operating manual

BA 030D/06/e/01.97

Nr. 50083821

valid from software version

V 1.07.00

Nothing beats know-how

HauserEndress

Flowjack ZX 6000

2Endress+Hauser

Contents

1 Safety Instructions . . . . . . . . 5

1.1 Correct usage . . . . . . . . . . . . 5

1.2 Dangers and notes . . . . . . . . . . 5

1.3 Personnel for installation, commissioning

and operation . . . . . . . . . . . . 5

1.4 Technical improvements . . . . . . . . 6

2 System Description . . . . . . . . 7

2.1 Application . . . . . . . . . . . . . . 7

2.2 Function principle . . . . . . . . . . . 7

2.3 Flowjack ZX 6000 simulator system . . . . 8

2.4 Terminal heads . . . . . . . . . . . . 9

3 Connections and Commissioning . . 11

3.1 Connection to the Promag 30/33/35 S . . 11

3.2 Connection to the Dosimag . . . . . . 12

3.3 Connection to the Promass 60/63 A, M, F . 12

3.4 Connection to the Prowirl 70 . . . . . . 13

3.5 Connection to the Variomag

(Picomag, Picomag II, Discomag, Pulsmag V) 13

3.6 Connection to the Tecmag

(Picomag II T, Discomag T, Pulsmag T) . . 15

3.7 Connection to the Speedmag

(Picomag, Picomag II, Discomag) . . . . 15

3.8 Connection to the Autozero 3000 . . . . 16

3.9 Connection to the Autozero 2000 . . . . 16

3.10 Connection to the Pulsmag . . . . . . 17

3.11 Connection to the m-point . . . . . . . 17

3.12 Anschluß des Swingwirl II . . . . . . . 18

3.13 Commissioning of the Flowjack simulator . 18

4 Operation . . . . . . . . . . . . 19

4.1 Operating and display elements . . . . 19

4.2 Input of important parameters . . . . . 20

4.3 Parameter input (flow charts) . . . . . 21

4.4 Programming example Promag 30/33 . . 32

5 Troubleshooting, Maintainance . . 35

5.1 Response of the Flowjack to faults . . . 35

5.2 Battery replacement . . . . . . . . . 36

5.3 Operating the power supply unit . . . . 36

5.4 Fuse replacement . . . . . . . . . . 37

5.5 Operating language selection

German/English . . . . . . . . . . . 38

6 Technical Data . . . . . . . . . . 39

Flowjack ZX 6000

Endress+Hauser 3

Flowjack ZX 6000

4Endress+Hauser

1 Safety Instructions

1.1 Correct usage

The Flowjack ZX 6000 is only to be used for simulation of sensor signals and may be

connected to E+H transmitters only. The device is used mainly by service personel,

who have understood the function and use of the device.

The manufacturer assumes no liability for damage caused by incorrect use of the

instrument.

Warning!

The Flowjack ZX 6000 may not be used in explosion hazardous area.

1.2 Dangers and notes

All instruments are designed to meet state-of-the-art safety requirements, have been

tested, and have left the works in an operationally perfectly safe condition. The de-

vices were developed according to EN 61010 “Protection Measures for Electronic

Equipment for Measurement, Control, Regulation and Laboratory Procedures”. A haz-

ardous situation may occur if the instrument is not used for the purposes it was de-

signed for or is used incorrectly. Please carefully note the information provided in the

operating manual indicated by the pictograms:

Warning!

A “warning” indicates actions or procedures which, if not performed correctly, may

lead to personal injury or a safety hazard.

Please strictly observe the instructions supplied and proceed carefully.

Caution!

A “caution” indicated actions or procedures which, if not performed correctly, may

lead to faulty operations or the destruction of the instrument.

Please strictly observe the respective instructions.

Note!

A “note” indicates actions or procedures which, if not performed correctly, may

indirectly affect operations or lead to an unexpected instrument response.

1.3 Personnel for installation, commissioning and operation

•Mounting, electrical installation, start-up, operation and maintainance of the instru-

ment may only be carried out by trained personnel authorized by the operator of the

facility. Personnel must absolutely and without fail read and understood this opera-

ting manual before carrying out its instructions.

•The service technician has to make sure that the instrument is correctly wired up

acording to its wiring diagrams.

•Please observe all provisions valid for your country and pertaining to the opening

and repairing of electrical devices.

Caution!

Note!

Flowjack ZX 6000 1 Safety Instructions

Endress+Hauser 5

1.4 Technical improvements

The manufacturer reserves the right to modify technical data without prior notice. Your

local E+H sales office will supply you with all current information and any updates to

this operating manual.

1 Safety Instructions Flowjack ZX 6000

6Endress+Hauser

2 System Description

2.1 Application

The Flowjack ZX 6000 is a flow signal simulator, which simulates the electrical signals

of the E+H sensors.

Its usage is mainly for checking the functions of the E+H sensors and transmitters

and in this way is used by service technicians.

The simulation system has been designed to be compatible with all E+H flow measur-

ing systems. A specific terminal head exists for each type of flowmeter.

2.2 Function principle

A flow measuring system is comprised of a sensor and the transmitter electronics.

The sensor has the function of generating a proportional electrical signal (e.g. a

voltage). This signal is subsequently amplified by the transmitter electronics and

converted into a measuring value that can be utilized by the end-user. The signals

generated by the sensor are dependent on the applied technology of the device itself

and on the characteristics of each individual flowmeter, for example, the calibration

factor and the zero point of the sensor. If all necessarey parameters are known and

programmed into the Flowjack, the sensor signal can be calculated in accordance

with the selected flow. This is exactly what is achieved by the Flowjack, thus making it

possible to check the function of the sensor, transmitter and following devices.

When the Flowjack is connected to the flowmeter the signal line (connection) between

the sensor and the transmitter electronics is separated (normally by plugs). After this

the appropriate terminal head is connected at their place. The sensor coil system

remains in operation during this time. By means of the coding of the terminal head,

the Flowjack is able to recognize the correct type of sensor itself. Now the program-

ming of the Flowjack can be carried out.

Figure 1 shows the connection of an electromagnetic measuring system.

Sensor

Transmitter electronics

Open connection signal line

Flowjack

Coil current cable

ba030y01

Fig. 1

Function principle by the

example of an electromagnetic

measuring system

Flowjack ZX 6000 2 System Description

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2.3 Flowjack ZX 6000 simulator system

A complete simulation system consists of the simulator Flowjack ZX 6000 and a

number of terminal heads for the different sensors. It is by means of these terminal

heads that the Flowjack is connected to different types of sensors.

The simulator system is suitable for all of the flow measurement principles that are

presently offered by E+H, namely, electromagnetic, vortex and mass flow-meter sys-

tems.

All components are delivered in a convenient synthetic case:

•Flowjack ZX 6000

•Power supply (optional)

•Operating manual

•Short operating table

•Terminal heads for Promag 30/33, Promag 35S, Promass 60/63 A/M/F, Prowirl 70

The Flowjack simulator generates the signals necessary for flow simulation. The de-

vice is microprocessor-controlled and is simple to operate via a user-friendly keypad

(5-keys). The entry of the parameters is in dialogue form. The parameters appear on a

2-line (each of 16 characters) LCD. The operating language can be either german or

English, and is changed by means of a switch.

When a terminal head is connected the Flowjack automatically switches on and inde-

pendently recognizes the type of device to which it has been connected. The simula-

tor remains switched on for as long as the terminal head is connected..

The voltage supply for the Flowjack is provided by either a 9 V battery, or an an appro-

priate power supply unit (not included in delivery).

ba030y02

Fig. 2

Case, flow simulator, power sup-

ply (optional) and accessories

2 System Description Flowjack ZX 6000

8Endress+Hauser

2.4 Terminal heads

Signals generated by the Flowjack are fed into the amplifier input of the converting

electronics by way of terminal heads. This is done by first disconnecting the plug-in

connections of the actual flowmeter and then connecting the cables of the terminal

head (counter connector) in their place.

The following terminal heads are available:

•Promag 30/33 (Dosimag)

•Promag 35 S

•Prowirl 70

•Swingwirl II

•Promass A/M/F

•m-point

•Tecmag

•Autozero 3000

•Autozero 2000

•Variomag (2 versions: with and without including the preamplifier)

•Speedmag

•Pulsmag

The terminal heads are labled with the name of the corresponding sensor. They are

located in the core part of the case.

Flowjack ZX 6000 2 System Description

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2 System Description Flowjack ZX 6000

10 Endress+Hauser

3 Connections and Commissioning

Warning!

The Flowjack may not be used in explosion hazardous area. Devices which are

connected to power supply may not be opened in explosion hazardous area.

If it is necessary to check a device by means of the Flowjack, this has to be done

outside the explosion hazardous area.

Depending on the sensor, the appropriate terminal head is first selected and then

connected to the transmitter electronics. The terminal heads are labeld with a name

plate.

The signal line between sensor and transmitter electronics will be separated, normally

by means of plugs, and the appropriate terminal head will be connected in their

place. The transmitter electronics and the sensor coil system remain in operation.

Now the terminal head is connected to the Flowjack and switches on automatically.

The simulator can now be programmed (see Chap. 4).

The following chapters describe the connection of the terminal heads to the different

transmitter electronics.

3.1 Connection to the Promag 30/33/35 S

•Open the transmitter housing

•remove female connector from male connector V5 and V6 on the amplifier board

•connect terminal head to the male connector

•attach crocodile clip to ground

There are two different terminal heads, one for Promag 30/33 and another for Promag

35 S.

TP2 TP

Iref

TP

Feld

V6

V5

Terminal head

ba030y03

Fig. 3

Connection to the

Promag 30/33/35 S

Flowjack ZX 6000 3 Connections and Commissioning

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3.2 Connection to the Dosimag

•Open the electronics housing

•remove electrode signal cable from the male connector

•connect terminal head (Promag 30/33) to the two male connectors of the amplifier board

•attach crocodile clip to ground

3.3 Connection to the Promass 60/63 A, M, F

•Open the electronics housing

•remove female connector from male connector V1 and V8 of the amplifier board

•connect terminal head to the male connector

•attach crocodile clip to ground

TP2

TP

Iref

TP

Feld

terminal head

ba030y07

Fig. 4

Connection to the Dosimag

V8

V1

Terminal head

ba030y04

Fig. 5

Connection to the Promass 60/63

3 Connections and Commissioning Flowjack ZX 6000

12 Endress+Hauser

3.4 Connection to the Prowirl 70

•Unscrew transmitter housing from the sensor stand

•connect terminal head to the connection board from below

•Make sure of the correct orientation of the coding pin.

3.5 Connection to the Variomag

(Picomag, Picomag II, Discomag, Pulsmag V)

Compact and S version

•Open electronics housing

•remove electrode signal cable from the male connector

•connect terminal head to the amplifier board according to the figure below

Coding pin

Terminal head

ba030y05

Fig. 6

Connection to the Prowirl 70

ba030y08

Terminal head

Fig. 7

Connection to the Variomag,

Compact and S version

Flowjack ZX 6000 3 Connections and Commissioning

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Connection to the LS and Ex versions (not including the preamplifier of the

sensor)

•Open electronics and terminal housing

•remove electrode signal cable from the male connector

•connect terminal head according to the figure below

•in terminal compartement connect: terminal 2 = signal and terminal 5 = ground

Connection to the LS and Ex version (including the preamplifier of the sensor)

For simulation both the preamplifier of the sensor as well as the transmitter electronics

are included. Therefore both devices have to be placed together according to the ca-

ble length of the terminal head.

•Open electronics and preamplifier housing

•remove electrode signal cable from the male connector of the preamplifier board

•connect terminal heads according to the figure below

Terminal head

2 = signal

5 = ground

ba030y09

Fig. 8

Connection to the Variomag (LS

and Ex) without including the pre-

amplifier of the sensor

Terminal head

2 = signal

5 = ground

ba030y10

Fig. 9

Connection to the Variomag with

including the preamplifier of the

sensor

3 Connections and Commissioning Flowjack ZX 6000

14 Endress+Hauser

3.6 Connection to the Tecmag

(Picomag II T, Discomag T, Pulsmag T)

•Open wiring compartment and inner DAT housing

•remove plug of the electrode signal cable

•connect terminal head to the male connector according to the figure

3.7 Connection to the Speedmag

(Picomag, Picomag II, Discomag)

•Open electronics housing

•remove electrode signal cable from the male connector

•connect terminal head to the male connector on the amplifier board according to

the figure

terminal head

ba030y11

Fig. 10

Connection to the Tecmag

Terminal head

ba030y12

Fig. 11

Connection to the Speedmag

Flowjack ZX 6000 3 Connections and Commissioning

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3.8 Connection to the Autozero 3000

•Open electronics housing

•remove electrode signal cable from the male connector

•connect terminal head to the male connector on the amplifier board according to

the figure

3.9 Connection to the Autozero 2000

•Open electronics housing

•remove electrode signal cable from the male connector

•connect terminal head to the two male connectors on the amplifier board according

to the figure

Terminal head

ba030y13

Fig. 12

Connection to the Autozero 3000

Terminal head

ba030y14

Fig. 13

Connection to the Autozero 2000

3 Connections and Commissioning Flowjack ZX 6000

16 Endress+Hauser

3.10 Connection to the Pulsmag

•Open electronics housing of the Pulsmag

•remove the electrode signal cable from the male connector

•connect terminal head to the two male connectors on the amplifier board according

to the figure

3.11 Connection to the m-point

•Remove cover of the electronics housing

•remove plug without coloured point and plug with red and green point from the

amplifier board

•connect the 3 adapters of the terminal head to the male connectors of the amplifier

board according to the figure

•attach crocodile clip to ground

Terminal head

ba030y01ba030y01

ba030y16

Fig. 14

Connection to the Pulsmag

ba030y06

Terminal head

Fig. 15

Connection to the m-point

Flowjack ZX 6000 3 Connections and Commissioning

Endress+Hauser 17

3.12 Connection to the Swingwirl II

•Open electronics housing of the Swingwirl II

•remove the sensor signal cable from the male connector

•connect terminal head to the male connector on the electronics board according to

the figure

3.13 Commissioning of the Flowjack simulator

The voltage supply for the Flowjack is provided by either a 9 V battery or an appropri-

ate power supply (not included in delivery) see Chap. 5.2.

The Flowjack switches automatically on when the terminal head is connected.

By means of the coding of the terminal heads the device type is recognized

automatically. Afterwards the programming of the Flowjack has to be carried out

(see Chap. 4) for calculating a correct flow signal.

ba030y15

Terminal head

Fig. 16

Connection to the Swingwirl II

ba030y17

Fig. 17

Switching on the Flowjack by

connecting the terminal head

3 Connections and Commissioning Flowjack ZX 6000

18 Endress+Hauser

4 Operation

4.1 Operating and display elements

Note!

The Flowjack case contains a short programming manual with all necessary data and

notes.

The LCD comprises two lines each with 16 characters. Messages in plain languge ap-

pear on it, as well as error messages. In operation the simulated signal is shown.

When entering parameters or numbers a cursor appears on the bottom of a character

which can be moved by the arrow keys.

The flowjack is operated by a 5 keys keypad. By means of the keys parameters are

selected, numbers are entered, changed and stored.

Note!

E+HFLOWTEC

SENSORSIMULATOR

Moving the cursor to the right position

Scrolling between parameters,

changing numbers, selecting units

Storing and terminating a data input

(only possible when the cursor

is not in ↕position)

Fig. 18

Front view of the Flowjack

Flowjack ZX 6000 4 Operation

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4.2 Input of important parameters

The parameters that are necessary for the simulation of the sensor signal differ ac-

cording to the type of sensor being used. The parameters are written on the name

plate of the flowmeter device in question or preferably can be called up on the trans-

mitter display. Following the aforementioned procedure ensures that parameters se-

lected are correct for simulating the desired flow conditions.

Important parameters for input are:

Device type Parameter

Electromagnetic measuring systemes

Promag 30/33

Promag 35 S

Variomag

Tecmag

Speedmag

Autozero 3000

Autozero 2000

Pulsmag

Nominal diameter (DN)

Full scale output or measuring range

Sensor zero point (PIPO)

Calibration factor (CALF)

Sensor zero point for reverse flow

direction (PIPN), only Variomag, Tecmag

Analog-ranging, only AZ 2000

Reference resistor, only Pulsmag

Mass flowmeter

Promass 60/63

m-point

Nominal diameter (DN)

Full scale output or measuring range

Sensor zero point (PIPO)

Calibration factor (CALF)

Vortes flowmeter

Prowirl 70

Swingwirl II

Full scale output or measuring range

Sensor constant

4 Operation Flowjack ZX 6000

20 Endress+Hauser

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Endres+Hauser Flowjack ZX 6000 Operating instructions

Endres+Hauser Flowjack ZX 6000 Operating instructions

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