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
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
Endress+Hauser 7
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
Endress+Hauser 9
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
Endress+Hauser 11
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
Endress+Hauser 13
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
Endress+Hauser 15
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
Endress+Hauser 19
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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