Electromagnetic Flowmeters

Electromagnetic Flowmeters

MagMaster

Instruction Manual –

BOOK 5 Fault Finding

ABB

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.

Use of Instructions

Warning.

An instruction that draws attention to the risk of injury or death.

Caution.

An instruction that draws attention to the risk of damage to the product, process or surroundings.

✶

Clarification of an instruction or additional information.

Information.

Further reference for more detailed information or technical details.

Although Warning hazards are related to personal injury, and Caution hazards are associated with equipment or property damage, it must be understood that operation of damaged equipment could, under certain operational conditions, result in degraded process system performance leading to personal injury or death. Therefore, comply fully with all Warning and Caution notices. 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 Marketing Communications Department.

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.

EN ISO 9001:2000 Cert. No. Q 05907 R E GISTERED EN 29001 (ISO 9001)

Lenno, Italy – Cert. No. 9/90A

0255 Stonehouse, U.K.

1

CONTENTS

Page

BOOK 5 FAULT FINDING

Section Page SAFETY MEASURES ... 1 1 INTRODUCTION ... 1 2 FAULT FINDING ... 2 2.1 Alarms ... 2 2.2 Test Mode ... 2 2.3 Fault Finding Flow Chart ... 3

A very powerful test mode, especially useful during commissioning and plant fault finding, enables all external devices connected to the MagMaster to be tested over the full range of flow rates.

This mode can be used regardless of flow conditions in the sensor, or even with the sensor disconnected, and does not require the use of additional equipment.

1

INTRODUCTION

SAFETY MEASURES

Warning.

• EXPLOSION HAZARD.

SUBSTITUTION OF COMPONENTS MAY IMPAIR SUITABILITY FOR CLASS I, DIVISION 2.

• EXPLOSION HAZARD.

DO NOT REMOVE FUSE OR DISCONNECT POWER LEADS WHILE CIRCUIT IS LIVE.

• THE LOCAL TERMINAL MUST NOT BE USED WHEN THERE IS AN EXPLOSION RISK.

Warning.

• Installation and maintenance must only be carried out by suitably trained personnel.

• HAZARDOUS AREA DESIGNATION ON THE EQUIPMENT LABEL MUST BE SUITABLE FOR THE INTENDED DUTY AND LOCATION.

• All relevant sections of this manual must be read before selecting a location.

• Safety requirements of this equipment, any associated equipment and the local environment must be taken into consideration.

• The installation and use of this equipment must be in accordance with relevant national and local standards.

MESURES DE SÉCURITÉ

Avertissement.

• RISQUE D’EXPLOSION.

SUBSTITUTION DE COMPOSANTS PEU RENDRE CE MATÉRIAL INACCEPTABLE POUR LES EMPLACEMENTS DE CLASSE I, DIVISION 2. • RISQUE D’EXPLOSION.

NE PAS RETIRER LE FUSIBLE NI DÉBRANCHER LES FILS D’ALIMENTATION TANT QUE LE CIRCUIT EST SOUS TENSION.

• NE PAS UTILIZEZ LE TERMINAL LOCAL EN ATMOSPHÈRE EXPLOSIVE.

2

FAULT FINDING

• Observe all safety measures (See INTRODUCTION). • Take all precautions to avoid risk to personnel, plant and

risk of explosion in hazardous areas.

• Do NOT open the transmitter main casing. There are no user serviceable parts or adjustments inside.

• Service access is restricted to the termination area Should the MagMaster fail to operate, first check the power supply, then the power supply connections and fuse located in the termination area. If necessary, replace the fuse with one of the correct rating as listed in Book 6.

✶

see Book 6.

Check that all external connections are made correctly.

2.1

Alarms

The transmitter has built in diagnostics with alarm indication which interrupts the transmitter local display. A data terminal connected to the transmitter will display these alarms in ‘Read Alm’ parameter; ‘16’ from Main Menu (see Warning in next column).

The table below shows possible alarm indications and Fig. 2.1 Fault Finding Flow Chart indicates checking procedures to find the problems causing the alarms.

For method of interrogating the local display see Startup Section in Book 4.

Table 2.1 Possible Alarm Indications

Display Alarm MtSnsr Empty Sensor

Hi High flow

Lo Low flow

Anlg Analogue over range

Pls Pulse frequency limited

Coil Sensor Coil open circuit

19, 20, 21 See Fault Finding Flow Chart

2.2

Test Mode

To access the Test Mode, connect a terminal device to the Programming Connector as described in APPENDIX A Section.

Select ‘Engineer’ security level (see Configuration Section). Set ‘Test Mode’ parameter to ‘1’ and enter an appropriate flow rate in the ‘Test Flow’ parameter.

Output responses may now be viewed from the various ‘Test’ parameters. (See Configuration Section for full details of operation.)

Warning. Refer to Safety Measures if a data

terminal is to be used to diagnose faults in hazardous locations.

3

FAULT FINDING

2.3

Fault Finding Flow Chart

ISS

.C

. 18:10:94

F

outB = REV Flo

w # F or full bore [B3] Pipe Siz e Flo w rate W rong ? Connect ter minal and chec k the follo wing Calibr ation fa ctors:

[462] = 1 Is the pipe full ?

man ual. [B51] Cal F act 1 see AquaProbe [461] = 1 meters . Otherwise # # Log-in at 'engineer' le v e l [31*engineer] When comm

unicating with MagMaster

all outputs and alar

ms . See Men u 'C' mode f o r setting flo w and testing Remember : MagMaster has a 'T est' Chec k cab le contin u ity been remo v e d ? microphonic screens Ha v e the Blac k anti-are correct. Chec k connections

the Sensor ter

m inals . the shor ting links to If alar m ceases mo v e T ransmitter . SIG2 to SIGGND at Shor

t circuit SIG1 &

Is the pipe full ?

clean electrodes & DS2 > 1 V o lt. If so , if v o ltage betw een DS1 Mtsnsr will be displa y ed w ater). V alue < 50 k ohms . (f or Ear th from SIG1/SIG2. measure resistance to ANALOGUE meter to If flo w present use an o. k . is > 50 then electrodes Mtsnsr mv [A2]. If v a lue If flo w is at z ero monitor T est f or f ouled Electrodes: Dir ty Electrodes ? Pls F a ct [61] If necessar y modify Read Pls Hz [64] is sending pulses chec k that MagMaster Connect T e rm inal and Note: F outA = FWD Flo w flo wr ate [C2]

[C1*1] and enter test

No - Select T est Mode ar angement. Y es - chec k connecting ALM2 = Re v erse Analogue O/P .

Dual Current option:

ALM ter

minal.

resistor in ser

ies with the

limit.

If so

, connect a 22 ohm

cause the output to current

Note:

Capacitiv

e loads ma

y

Open Collector Output.

compatib

le with the MagMaster

The remote equipment is

(Def ault) alar ms are de-selected. is selected and an y unw anted Chec k that the w anted alar m T w o Items to chec k -Alar m Prob lem: contain Red p .c.b's Note: D .C . MagMasters fuse .

and the MagMaster

Chec k po w er source is no po w e r.

functioning then there

If the displa y is not meter . Chec k against local from [54], Anlg mA. and read v a lue cab

les from MagMaster

correct. Remo v e If O/P current not < 600 ohms . loop resistance

Full Scale - Chec

k

Current cannot reach

Modify , if necessar y. and chec k Flo w Rng [41] Connect ter minal > 123456 m^ 12.34 Ltr/s ABB K ent-T a ylor Anlg 7 5 4 23 6 PLS 1 / Coil Mtsnsr Coil Mtsnsr Mtsnsr screens ha v e been remo v ed. Ensure b lac k anti-microphonic dr a w

ings in the Man

ual. Chec k Connections against is f aulty . Cab le o .k. Tx If Sensor and Resistance < 20 ohms Sensor Coil for CD1 & CD2 Cab le contin uity Chec k Sensor CD2 CD1 ALM1 & ALM2 Alar ms: Po w e r Connect RS232 Term inal to Comm unicate sho wn [ ] Men u commands with MagMaster RS232 contact ABB K-T If alar m persists [16*0] T o Reset: error . Configur ation 21-P ossib le error 20-P ossib le Memor y totaliz er error . 19-P o ssib le System Alar ms . 19 - 21 MagMaster Alar m is flashing-If Displa y Select Displa y Men u [73*1] T o enab le T o taliz er Reset MagMaster mA V

PRODUCTS & CUSTOMER SUPPORT

Products

Automation Systems

– Chemical & Pharmaceutical – Food & Beverage

– Manufacturing – Metals and Minerals – Oil, Gas & Petrochemical – Pulp and Paper

Drives and Motors

• AC and DC Drives, AC and DC Machines, AC motors to 1kV • Drive systems

• Force Measurement • Servo Drives

Controllers & Recorders

• Single and Multi-loop Controllers

• Circular Chart , Strip Chart and Paperless Recorders • Paperless Recorders

• Process Indicators

Flexible Automation

• Industrial Robots and Robot Systems

Flow Measurement

• Electromagnetic Flowmeters • Mass Flow Meters

• Turbine Flowmeters • Flow Elements

Marine Systems & Turbochargers

• Marine Equipment

• Offshore Retrofit and Refurbishment

Process Analytics

• Process Gas Analysis • Systems Integration

Transmitters

Valves, Actuators and Positioners

• Actuators • Positioners

Water, Gas & Industrial Analytics Instrumentation

sensors

• ammonia, nitrate, phosphate, silica, sodium, chloride, fluoride, dissolved oxygen and hydrazine analyzers. • Zirconia oxygen analyzers, katharometers, hydrogen purity

and purge-gas monitors, thermal conductivity.

Customer Support

We provide a comprehensive after sales service via a Worldwide Service Organization. Contact one of the following offices for details on your nearest Service and Repair Centre.

United Kingdom

ABB Limited

Tel: +44 (0)1453 826661 Fax: +44 (0)1453 829671

United States of America

ABB Inc.

Tel: +1 (0) 755 883 4366 Fax: +1 (0) 755 883 4373

Client Warranty

Prior to installation, the equipment referred to in this manual must be stored in a clean, dry environment, in accordance with the Company's published specification.

Periodic checks must be made on the equipment's condition. In the event of a failure under warranty, the following documentation must be provided as substantiation:

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

2. Copies of all storage, installation, operating and maintenance records relating to the alleged faulty unit.

IM/MM/BK5

Issue 6

ABB Limited

Oldends Lane, Stonehouse Gloucestershire GL10 3TA UK Tel: +44 (0)1453 826661 Fax: +44 (0)1453 829671 ABB Inc.

125 E. County Line Road Warminster

PA 18974 USA

Tel: +1 215 674 6000 Fax: +1 215 674 7183 ABB has Sales & Customer Support

expertise in over 100 countries worldwide www.abb.com

The Company’s policy is one of continuous product improvement and the right is reserved to modify the information contained herein without notice. Printed in UK (03.04) © ABB 2004