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ABB AquaMaster Instruction Manual

Electronic commercial water meter
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Installation Manual
Electronic Commercial Water Meter
IM/AM Issue 13
AquaMaster™

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Summary of Contents for ABB AquaMaster

  • Page 1 Installation Manual Electronic Commercial Water Meter IM/AM Issue 13 AquaMaster™...
  • Page 2 Cert. No. Q 05907 As a part of ABB, a world leader in process automation technology, we offer customers application expertise, service and support worldwide. EN 29001 (ISO 9001) We are committed to teamwork, high quality manufacturing, advanced technology and unrivalled service and support.

  • Page 3: Table Of Contents

    Replacing a Battery ....................... 36 4.4.1 Spares Kits ........................36 4.4.2 Battery Changing Procedures ..................37 Specification ..........................39 Appendix A GSM-Equipped Units – Safety Precautions ..............50 Appendix B AquaMaster Block Diagram ................... 51 Notes ..............................52 IM/AM Issue 13...

  • Page 4: Introduction

    Electronic Commercial Water Meter AquaMaster™ 1 Introduction 1 Introduction 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.

  • Page 5: Mechanical Installation

    Electronic Commercial Water Meter AquaMaster™ 2 Mechanical Installation 2 Mechanical Installation 2.1 Unpacking AquaMaster AquaMaster AquaMaster AquaMaster Fig. 2.1 Unpacking 2.2 Installation Conditions Caution. Do NOT exceed the maximum working pressure marked on the equipment. Fig. 2.2 Spillage Fig. 2.3 Vibration...
  • Page 6 Electronic Commercial Water Meter AquaMaster™ 2 Mechanical Installation Fig. 2.4 Localized Heat Allow room to read display Fig. 2.5 Siting >2 x pipe dia. >5 x pipe dia. minimum minimum Flow Direction Fig. 2.6 Straight Pipe Requirements IM/AM Issue 13...
  • Page 7 Electronic Commercial Water Meter AquaMaster™ 2 Mechanical Installation Fig. 2.7 Fluid Level 60°C (140°F) Maximum –20°C (–4°F) Minimum Fig. 2.8 Within Temperature Limits Fig. 2.9 Shade IM/AM Issue 13...
  • Page 8 Electronic Commercial Water Meter AquaMaster™ 2 Mechanical Installation Supports Fig. 2.10 Above Ground Fig. 2.11 Temperature Difference < 2m (78 in) Submerged 9 Months ­ Accrued Time IP68 (NEMA 6P/ ENCLOSURE 6P) Fig. 2.12 Within Environmental Rating IM/AM Issue 13...
  • Page 9 Electronic Commercial Water Meter AquaMaster™ 2 Mechanical Installation Adequate Protection Plate Backfill (Recommended) Fig. 2.13 Underground 80°C (176°F) Maximum –10°C (14°F) Minimum Fig. 2.14 Cable Routing Fit gaskets Gasket same size as pipe Fig. 2.15 Gasket Fitting IM/AM Issue 13...
  • Page 10 Electronic Commercial Water Meter AquaMaster™ 2 Mechanical Installation 0.7m (2.3 ft) minimum Fig. 2.16 Separation of Sensors For access to batteries, display and communication connector. Fig. 2.17 Access to Transmitter IM/AM Issue 13...

  • Page 11: Transmitter Dimensions

    Electronic Commercial Water Meter AquaMaster™ 2 Mechanical Installation 2.3 Transmitter Dimensions Dimensions in mm (in.) Installation and wiring access 300 (11.8) minimum 450 (17.7) preferred 176 (7) 146 (5.75) 125 (4.9) ø6.5 ( AquaMaster ø13 ( 155mm (6.7) (6.1) (5.5) (5.9)

  • Page 12: Gsm-Equipped Transmitters

    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.

  • Page 13: Connecting A Remote Antenna

    Electronic Commercial Water Meter AquaMaster™ 2 Mechanical Installation 2.4.2 Connecting a Remote Antenna If the transmitter is not fixed in any way, arrange or hold it with the top cover uppermost. Wash off any loose dirt from the case using plain water.

  • Page 14: Installing A Sim Card

    Electronic Commercial Water Meter AquaMaster™ 2 Mechanical Installation 2.4.3 Installing a SIM Card If the transmitter is not fixed in any way, arrange or hold it with the top cover uppermost. Wash off any loose dirt from the case using plain water.

  • Page 15: Electrical Installation

    Electronic Commercial Water Meter AquaMaster™ 3 Electrical Installation 3 Electrical Installation 3.1 Bonding/Grounding Caution. For safety reasons and optimum performance, the flowmeter, pipelines and medium must be correctly bonded and grounded according to regulations. Note. The flow sensor must not be connected to a ground spike.
  • Page 16 Electronic Commercial Water Meter AquaMaster™ 3 Electrical Installation See Figs. 3.6 and 3.7 Insulation Fluid Contact Rings Fig. 3.2 Metal Pipe With Flange Adaptor See Figs. 3.6 and 3.7 Fluid Contact Rings Fig. 3.3 Flanged Metal Pipe to Plastic Pipe...
  • Page 17 Electronic Commercial Water Meter AquaMaster™ 3 Electrical Installation See Figs. 3.6 and 3.7 Fluid Contact Rings Fig. 3.4 Metal Pipe With Plastic Make-Up Insert See Figs. 3.6 and 3.7 Fluid Contact Rings Fig. 3.5 All Plastic Pipe IM/AM Issue 13...
  • Page 18 Electronic Commercial Water Meter AquaMaster™ 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 IM/AM Issue 13...
  • Page 19 Electronic Commercial Water Meter AquaMaster™ 3 Electrical Installation Insulated connecting wire (not supplied). Must be adequately rated to carry cathodic currents. Bonding Cable (supplied) Insulating Sleeve and Washer Gasket Gasket (not supplied) Fluid Contact Bonding Cables Ring (supplied) Fluid Contact Rings Fig.
  • Page 20 Electronic Commercial Water Meter AquaMaster™ 3 Electrical Installation Insulated connecting wire (not supplied). Must be adequately rated to carry cathodic currents. Insulating Sleeve and Washer (not supplied) Bonding Cable Gasket (supplied) Fig. 3.9 Pipelines With Cathodic Protection, DN 40mm to 80mm Caution.

  • Page 21: Connections

    Electronic Commercial Water Meter AquaMaster™ 3 Electrical Installation 3.2 Connections 3.2.1 Sensor Terminal Box Connections (Remote Versions only) Caution. (Remote versions) Remove foil screens completely, and plastic/foil screens and any fillers Twist the three screen wires together and sleeve them.

  • Page 22: Environmental Protection

    Electronic Commercial Water Meter AquaMaster™ 3 Electrical Installation 3.2.2 Environmental Protection Fig. 3.11 Potting the Terminal Box 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.

  • Page 23: Transmitter Connections

    Electronic Commercial Water Meter AquaMaster™ 3 Electrical Installation 3.2.3 Transmitter Connections Caution. To ensure cable glands seal, use cable of diameter 2 to 6mm (0.08 to 0.24 in) [M16] only. Ensure cable glands are tightened after wiring. However, overtightening a plastic cable gland will break it and destroy its sealing property.
  • Page 24 Electronic Commercial Water Meter AquaMaster™ 3 Electrical Installation Fig. 3.13 Transmitter Connections (Glands/Conduit Entry) 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.
  • Page 25 Electronic Commercial Water Meter AquaMaster™ 3 Electrical Installation Fig. 3.15 Sensor Cable Connections (Connector, Remote version) Note. This arrangement is an option. IM/AM Issue 13...

  • Page 26: Input/Output Connections

    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.

  • Page 27: Alarm Interface

    Electronic Commercial Water Meter AquaMaster™ 3 Electrical Installation 3.3.2 Alarm Interface I/P0V* Common Alarm Input O/P3 *Optional link for grounding floating output. See Caution above. Fig. 3.17 Alarm Output Connections Note. Output 3 is not polarity sensitive. The common connection for these outputs is designated ‘COM’.

  • Page 28: Connector Input/Output Connections

    Electronic Commercial Water Meter AquaMaster™ 3 Electrical Installation 3.3.3 Connector Input/Output Connections Fig. 3.18 MIL Connector Connections Signal Function Color (Output Cable) – Reserved – Reserved – Reserved O/P 1 Forward Pulses or Forward & Reverse Pulses Orange O/P 3...

  • Page 29: Mil Connector Input/Output (Option) Aquamag™ X10 Pulse Output Compatibility

    Note. Some data logger leads contain components which convert forward and reverse pulses into a single pulse line with a direction signal. Such leads will NOT work with AquaMaster and are unnecessary as AquaMaster directly provides the correct signals for these loggers.

  • Page 30: Local Computer Connection

    Electronic Commercial Water Meter AquaMaster™ 3 Electrical Installation 3.3.6 Local Computer Connection Connected to 9-pin Serial Data socket on PDA or PC via 'Laplink' lead/adaptor Original Style ABB Limited Part No.WEBC2000 Current Style 9-pin female (direct to PC) 9-pin male (for link lead to Psion) Fig.

  • Page 31: Remote Computer Connection

    Signal (DTE) Name DB25 Name DB25 – * Also mates with PDA PC-Link cables Table 3.2 RS232 Connections AquaMaster Transmitter Connector Block Layout Radio Modem (Radio Pad), Computer or similar Current Design Modem Early Design* (see Note below) Fig. 3.22 RS232 Connections...

  • Page 32: Power Supply Connection

    Electronic Commercial Water Meter AquaMaster™ 3 Electrical Installation 3.3.8 Power Supply Connection Warning. DISCONNECT THE SUPPLY FROM ANY CABLES BEING TERMINATED ON THE TRANSMITTER. Electrical installation and earthing (grounding) must be in accordance with relevant national and local standards. Note. Power supply connections/earthing arrangements are identical for cathodically protected remote transmitter systems.

  • Page 33: Pressure Transducer (Optional)

    Pressure Transducer Connector Fig. 3.24 AquaMaster fitted with Optional PressureTransducer Connector Caution. Use only the pressure transducer supplied with the transmitter. Use of other pressure transducers will require alteration of the pressure span and zero factors in the transmitter – see Quick Reference Programming guide.

  • Page 34: Environmental Protection

    Electronic Commercial Water Meter AquaMaster™ 3 Electrical Installation 3.3.10 Environmental Protection Warning. Potting materials are toxic – use suitable safety precautions. Read the manufacturers instructions carefully before preparing the potting material. Fig. 3.25 Potting the Transmitter Caution. For IP68 protection against water ingress, pot the termination area on the metal transmitter versions.

  • Page 35: Start-Up And Operation

    The battery used in this device may present a risk of fire or chemical burns if mistreated. Do not recharge, disassemble, heat above 100°C or incinerate. Replace battery pack with an ABB supplied part only. Use of another battery may present a risk of fire or explosion.
  • Page 36 Electronic Commercial Water Meter AquaMaster™ 4 Start-Up And Operation AquaMaster Transmitter Current Model (top cover removed) 1) Remove the top cover of the transmitter – see Fig. 3.12. 2) Connect the battery or batteries to the wire connector(s) inside the top of the transmitter unit.

  • Page 37: Display Activation

    Electronic Commercial Water Meter AquaMaster™ 4 Start-Up And Operation Upper Display Date Forward Flow Total Pictorial Displays Reverse Flow Total Warning annunciators 88888. 8 88. Net Flow Total Left Battery Warning Lower Display . 8 . 8 . 8 . 8 0...

  • Page 38: Replacing A Battery

    Electronic Commercial Water Meter AquaMaster™ 4 Start-Up And Operation 4.4 Replacing a Battery Note. Each battery must be connected to the cable from the same side of the termination area as the battery position in the battery holder or lid. For dual battery units, replace only the battery indicated by the battery legend described below.

  • Page 39: Battery Changing Procedures

    Electronic Commercial Water Meter AquaMaster™ 4 Start-Up And Operation 4.4.2 Battery Changing Procedures Note. Before changing batteries in a dirty environment it is recommended that, in order to minimize contamination, the new O-ring is fitted to the new lid assembly (or cleaned lid assembly from a previous installation) in a clean area, and the lid sealed in a polythene bag.
  • Page 40 Electronic Commercial Water Meter AquaMaster™ 4 Start-Up And Operation Clean the transmitter with plain water. Small amounts of soiling may be removed with a wet tissue. 2 Remove the transmitter top cover (see Fig. 3.12) to reveal the batteries clipped in the cover.

  • Page 41: Specification

    Electronic Commercial Water Meter AquaMaster™ 5 Specification 5 Specification Battery-powered Meters – Flow Requirements per ISO 4064 (Standard Version) Size max. (0.5%) min. /h (Ugal/min) /h (Ugal/min) /h (Ugal/min) /h (Ugal/min) /h (Ugal/min) 3 (13) 1.5 (7) 0.23 (1.0) 0.023 (0.099) 0.009 (0.040)
  • Page 42 Electronic Commercial Water Meter AquaMaster™ 5 Specification Battery-powered Meters – Flow Requirements per CEN pr 14154 and latest ISO4064 (Standard Version) Size (0.25%) /h (Ugal/min) /h (Ugal/min) /h (Ugal/min) /h (Ugal/min) /h (Ugal/min) 5 (22) 4 (18) 0.23 (1.0) 0.025 (0.110) 0.010 (0.044)
  • Page 43 Electronic Commercial Water Meter AquaMaster™ 5 Specification Flow Requirements per CEN pr 14154 (Bulk Revenue Version) Size /h (Ugal/min) /h (Ugal/min) /h (Ugal/min) /h (Ugal/min) 50 (220) 40 (176) 1 (4.4) 0.4 (1.8) 79 (247) 63 (277) 1.6 (7) 0.63 (2.8)
  • Page 44 Electronic Commercial Water Meter AquaMaster™ 5 Specification Wetted Materials Screw end meters Brass Flanged meters Electrodes – stainless steel 316L Lining Suitable for potable water (UKWFBS listed) Pressure limitations As flange rating Conductivity >50µS/cm End Connections Thread end connections 15mm – G in.
  • Page 45 2 batteries – typically 3 years, extended life is possible to give, say, 5 years for two cells with a small degradation in response time and slightly increased measurement uncertainty, contact ABB for details. Battery life is shorter with GSM, depending on how frequently it is used and for what period. For example, used once per day for SMS automated reporting of data logged at 15 minute intervals, the total life of 2 batteries would be typically reduced to approximately 2 years.
  • Page 46 Pulse output 50Hz maximum, 50% nominal duty cycle Serial data communications Local Port RS232 compatible via ABB lead (Option) Remote Port (Option) RS232 with RI, RTS and CTS handshaking for connection to a modem or computer Telemetry applications using remote serial data communications...
  • Page 47 Languages English French German Spanish Italian Dutch Other languages can be added via Windows download Program (contact ABB) GSM Antenna Mounting Integral with transmitter Remote (1m cable) Antenna environmental IP66 (NEMA4) waterproof for accidental submersion (Note. The GSM does not operate with integral antenna under water)
  • Page 48 Electronic Commercial Water Meter AquaMaster™ 5 Specification Mounting 45° maximum Sensor Electrodes Pipe Conditions >5 x pipe dia. >2 x pipe dia. minimum minimum Flow Direction IM/AM Issue 13...
  • Page 49 Electronic Commercial Water Meter AquaMaster™ 5 Specification Default Settings Table Configuration Parameter Default European Default North American Pulse Factor Pulse Units Ugal Totalizer Units Ugal Full Scale Flow ISO 4064 Qn ISO 4064 Qn Flow Units MUGD Velocity Units ft/s...
  • Page 50 Electronic Commercial Water Meter AquaMaster™ 5 Specification Sensor Specification (nominal dimensions) 15 to 25mm (0.5 to 1 in.) – Screw Ends Meter Size Dimensions mm (in) Connection Approx. Weight 119 (4.7) in. B or in.NPSM 0.75 127 (5) G 1in. B or 1 in. NPSM 127 (5) in.
  • Page 51 Electronic Commercial Water Meter AquaMaster™ 5 Specification 350 to 600mm (14 to 24 in.) – Flanged Meter Size Dimensions mm (in) Approx. Weight 513 (20.2) 520 (20.5) 550 (21.7) 570 (22.4) 576 (22.7) 600 (23.6) 632 (24.9) 627 (24.7) 698 (27.5) 686 (27.0)

  • Page 52: Appendix A Gsm-Equipped Units - Safety Precautions

    Electronic Commercial Water Meter AquaMaster™ Appendix A GSM-Equipped Units – Safety Precautions Appendix A GSM-Equipped Units – Safety Precautions Safety Precautions The following safety precautions must be observed during all phases of the operation, usage, service or repair of this GSM cellular terminal. Failure to comply with these precautions violates safety standards of design, manufacture and intended use of the product.

  • Page 53: Appendix B Aquamaster Block Diagram

    Electronic Commercial Water Meter AquaMaster™ Appendix B AquaMaster Block Diagram Appendix B AquaMaster Block Diagram IM/AM Issue 13...

  • Page 54: Notes

    Electronic Commercial Water Meter AquaMaster™ Notes Notes IM/AM Issue 13...
  • Page 55 – Chemical & Pharmaceutical Repair Centre. – Food & Beverage – Manufacturing – Metals and Minerals ABB Limited – Oil, Gas & Petrochemical Tel: +44 (0)1453 826661 – Pulp and Paper Fax: +44 (0)1453 829671 Drives and Motors ABB Inc.
  • Page 56 ABB has Sales & Customer Support expertise The Company’s policy is one of continuous product in over 100 countries worldwide improvement and the right is reserved to modify the information contained herein without notice. www.abb.com Printed in UK (12.07) © ABB 2007 ABB Limited ABB Inc.

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