MAG-SM Electromagnetic Flowmeter

FILL-MAG with AC Magnetic Field

Excitation
Models: DS21_ / DS4_F

Instruction Bulletin D184B064U02 Rev. 03 / 08.02

For Converters:
MAG-SM Model 50SM1000
FILL-MAG Model 50ES7000
 You have purchased a high quality, modern Electromagnetic Flowmeter System
from ABB Automation. We appreciate your purchase and the
confidence you have expressed in us.
This Instruction Bulletin contains information relating to the assembly and
installation of the instrument and the specifications as well the testing of this
instrument design. ABB Automation reserves the right to make hardware and software
improvements without prior notice. Any questions which may arise that are not
specifically answered by these instructions should be referred to our main plant in
Göttingen, Germany or to one of our Technical Sales Bureaus.
Their addresses, telephone and FAX numbers may be found on the back cover.

This interference resistance of this converter complies with the

NAMUR-Recommendations “EMC-Guidelines for Manufacturers
and Users of Electrical Instruments and Equipment “
Part 1, 5/93 and EMC-Guideline 89/336/EWG
(EN50081-1, EN50081-2)

Copyright by ABB Automation. All rights reserved.

Introductory Safety Notes for the EMF System
Regulated Usage
The Electromagnetic Flowmeter System (EMF) is manufactured to state of the art designs and is safe to
operate.
The flowmeter is to be installed exclusively in applications which are in accord with the specifications.
Every usage which exceeds the specifications is considered to be non-specified. Any damages resulting
therefrom are not the responsibility of the manufacturer.
The user assumes all risk for such usage.
The applicable specifications include the installation, start-up and service requirements specified by the
manufacturer.
Assembly, Start-Up and Service Personnel
Please read this Instruction Bulletin and the safety notes before attempting installation, start-up or service.
Only qualified personnel should have access to the instrument.
The personnel should be familiar with the warnings and operating requirements contained in this
Instruction Bulletin.
Assure that the interconnections are in accordance with the Interconnection Diagrams. Ground the
flowmeter system.

Observe the warning notes designated in this document by the symbol:

Hazardous Material Information

If a repair is required, the following information should be noted:
In view of the Disposal Law of 27 Aug. 86 (AbfG. 11 Special Wastes) the owner of special wastes
is responsible for its care and the employer also has, according to the Hazardous Material Law of
01 Oct. 86 (GefStoffV, 17 General Protection Responsibility), a responsibility to protect his employees, we
must make note that
a) all flowmeter primaries and/or flowmeter converters which are returned to ABB Automation Products for
repair are to be free of any hazardous materials (acids, bases, solvents, etc.).
b) the flowmeter primaries must be flushed so that the hazardous materials are neutralized. There
are cavities in the primaries between the metering tube and the housing. Therefore after metering
hazardous materials, these cavities are to be neutralized (see Hazardous Material Law -GefStoffV). For
two piece housings the housing screws should be loosened. For flowmeter primaries ≥ 14"/DN 350 the
drain plug at the bottom of the housing is to be removed in order to neutralize any hazardous material
in the magnet coil and electrode areas.
c) for service and repairs written confirmation is required that the measures listed in a) and b) have been
carried out.
d) any costs incurred to remove and neutralize the hazardous materials during a repair will be billed to the
owner of the equipment.
 Contents Page

1. Flowmeter Primary and Converter Coordination .................................................... 1

1.1 Application Areas for MAG-SM ............................................................................................................... 1
1.2 Application Areas for FILL-MAG ............................................................................................................. 1
1.3 Model Number Coordination ................................................................................................................... 1
1.4 Instruction Bulletins ................................................................................................................................. 1
1.5 Specification Sheets, Metering System MAG-SM ABB Part No.:D184S034U01 Rev.01 Fill-MAG
D184S033U01 ........................................................................................................................................ 1

2. Overview, Flowmeter Primary Designs ................................................................... 2

3. Functional Description .............................................................................................. 3

4. Assembly and Installation ........................................................................................ 4

4.1 Inspection ............................................................................................................................................... 4
4.2 Installation Requirements Flowmeter Primary ........................................................................................ 4
4.2.1 Installation of the Flowmeter Primary ..................................................................................................... 6
4.2.2 Installations for Protection Class IP 68 ................................................................................................... 8
4.2.3 Installation of the High Temperature Design .......................................................................................... 8
4.2.4 Installation in Larger Size Pipelines ........................................................................................................ 8
4.2.5 Installation of the Certified Designs ........................................................................................................ 9
4.3 Replaceable Parts List, Connection Box, Aluminum Housing ≤ 12” / DN 300 ........................................ 11
4.4 Replaceable Parts List, Connection Box, Aluminum, Flowmeter Primary 14” - 16” : DN 350 - 400 ....... 12
4.5 Replaceable Parts List, Connection Box, Aluminum, Flowmeter Primary ≥ 20” : DN 500 ...................... 13
4.6 Replaceable Parts, Flowmeter Primary .................................................................................................. 14
4.7 Replaceable Parts List with Preamplifier ................................................................................................ 15

5. Safety Relevant Section of the Instruction Bulletin ............................................... 16

5.1 Electrical Connections Anschluss ........................................................................................................... 16
5.1.1 Grounding ............................................................................................................................................... 16
5.1.2 Supply Power Connections ..................................................................................................................... 18
5.1.3 Magnet Coil Supply ................................................................................................................................. 18
5.1.4 Power Consumption ............................................................................................................................... 18
5.1.5 Signal Cable Connections ...................................................................................................................... 19
5.1.6 Interconnection Diagram ......................................................................................................................... 19
5.1.7 Connection Area ..................................................................................................................................... 20

6. Start-Up ....................................................................................................................... 22
6.1 Preliminary Checks ................................................................................................................................. 22
6.2 Zero Check ............................................................................................................................................. 22
6.3 Maintenance ........................................................................................................................................... 22

7. Testing and Error Search of the Flowmeter Primary Using the Converter*) ........ 23
 Flowmeter Primary, Model DS21_/DS4_F
1. Flowmeter Primary and Converter installed in the pipeline and a converter mounted separate-
ly. In order to assure trouble free operation it is essential to
Coordination assure that only converters Model Numbers 50SM1000 or
50ES7000 are connected to the flowmeter primary. The

!
complete Model Numbers are listed on the instrument tags
Note of the instruments.
This flowmeter system utilizes AC magnetic field excitation.
The metering system consists of a flowmeter primary which
is

Flowmeter System with AC Magnetic Field Excitation

1.1 Application Areas for MAG-SM 1.2 Application Areas for FILL-MAG
These electromagnetic flowmeters provide an economical and These electromagnetic flowmeters are especially designed for
precise means to meter the flow of liquids, slurries and sludges batch, fill and injection processes, for filling the smallest vol-
whose electrical conductivity is above 20 µS/cm (option, 0.5 µS/ umes all the up to the largest containers.
cm). The metering system is especially suitable for fast chang-
ing processes, two-phase liquids, continuous or pulsating flows 1.3 Model Number Coordination
(piston pump operation).

Flowmeter Primary Converter

Stainless Steel Housing Series 2000 MAG-SM 50SM1000

10DS2111/10DS2112, DS21_ Fill-MAG 50ES7000

Aluminum Housing Series 3000/4000 MAG-SM 50SM1000

10D1422/10DI1425/10DS3111/ Fill-MAG 50ES7000
10DS3112/10DS3121/DS41F/DS44F

1.4 Instruction Bulletins

Flowmeter Primary Converter

ABB Part No.: D184B064U01 Rev.02 MAG-SM ABB Part No.: D184B085U01 Rev.01
Fill-MAG D184B066U01

1.5 Specification Sheets, Metering System MAG-SM ABB Part No.: D184S034U01 Rev.01
Fill-MAG D184S033U01

1
Flowmeter Primary, Model DS21_/DS4_F
2. Overview, Flowmeter Primary Designs
Variable Connections Connection Types Fixed Flange Wafer Design Fixed Flange

Weld stubs Hose connector

Pipe fitting External threads

1/10”–1-1/2” / DN3-DN40 Food industry fitting
1/10”–1-1/2” / DN3-DN40
Tri-Clamp Internal threads

Flange PVC-Cement sleeve

SMS-Fitting Fixed-Clamp
2”–4” / DN 50–DN 100
See Spec. Sheet for more,
others upon request 2”–4” / DN 50–DN 100
Accuracy 1 % of rate
Flowmeter primary housing mat’l Stainless Steel Housing Complete Series 2000 Alum Hsg. Series 4000
Flowmeter Primary
Model Number DS21* DS21F DS21W DS41F
Process Connections Inch DN PN * Meter Size Pres. Rtg. Inch DN PN Meter Size Pres. Rtg.
Wafer Design – W – 1/10–4 3–100 10–40 –
Flanges DIN 2501 – F DN 3-100 PN10-40 – DN 3–2000 PN 10–40
Flanges ANSI B16.5 1/10–4 3–100 10 F 1/10”–4” CL 150–300 – 1/10”–40” CL 150–300
Flanges FAB1B DIN 11864-2B 1/10–4 3–100 16 L – – –
Aseptic connection. DIN 11864-1B 1/10–4 3–100 10-40 A – – –
Food Industry fitting. DIN 11851 1–4 25–100 16 S – – –
Threaded connection. SMS 1145 1–4 25–100 16 D – – –
Weld stubs DIN 11850 1/10-4 3–100 10 R – – –
Weld stubs DIN 2463 1/10-4 3–100 10 Q – – –
Weld stubs ISO 2037 1–4 25–100 40 P – – –
Tri-Clamp DIN 32676 1–4 25–100 10 T – – –
Tri-Clamp ISO 2852 1/10-4 3–100 10-40 U – – –
Fixed clamp 3/8–1-1/2 10–40 10 C – – –
External threads ISO 228 1/10–1 3–25 10 E – – –
Internal threads ISO 228 1/10–1 3–25 10 I – – –
PVC-Cement sleeve 1/10–1 3–25 10 G – – –
Hose connector 1/10–1/2 3–15 10 H – – –
1/8” Sanitary connector 1/25–3/32 1–2 10 B – – –
Liner PEEK, Torlon (<1/10” : DN3) PFA PFA Hard and soft rubber,
PFA (>3/32” : DN2) PTFE, PFA, others
Conductivity ≥ 20 µS/cm Option ≥ 0.5 µS/cm
Electrodes SS 316Ti/1.4571, SS 1.4539, Hastelloy B-2/C-4, Platinum-Iridium, Tantalum, Titanium
Process connection material SS316L/1.4404, 304/1.4301 SS 316Ti/1.4571 – Steel, SS 316Ti/1.4571
Protection Class per EN 60529 IP 67 / IP 68 IP 67 / IP 68 IP 67 / IP68 IP 67 / IP 68
Fluid temperature -25 to 130 °C -40 to 130 °C -25 to 130 °C -25 to 130 °C/180°C
Approvals
Hygienic and sterile requirements CIP/SIP-capable FML, 3A, EHEDG (Cleanability) CIP-capable

! Note
The maximum signal cable length between the flowmeter
primary and the converter is 50 m. When a preamplifier is
installed for low conductivity applications the max. signal
cable length is 200 m. The flow velocity must be reduced, <
1 m/s, when the fluid conductivity is low and the εr value is
high (for demineralized water εr = 78).

2
 Flowmeter Primary, Model DS21_/DS4_F
3. Functional Description shows that the signal voltage UE is linear and proportional to
the volume flowrate.
ABB Automation Electromagnetic Flowmeters »EMF« are the
ideal flow metering instruments for liquids, slurries and sludges UE ~ qv
which have a specific minimum electrical conductivity. The
instruments measure accurately, add no additional pressure Design
drop, have no moving or protruding parts, are wear free and An electromagnetic flowmeter system includes a flowmeter
chemically resistant. The flowmeters can be readily installed in primary and a converter. The flowmeter primary is installed
existing pipelines. in the pipeline while the converter which processes the flow
signals can be mounted locally or in a central control room.
The ABB Automation EMFs have been proven over many years
of service and are the preferred flowmeters in the Chemical
Industry, Municipal Water and Waste Water treatment facilities,
the Food and Beverage Industry as well as in the Pulp and
Paper Industry.
! Note:
Please observe the specified coordination between the
flowmeter primaries and the converters shown on Page 1.

Principle of Operation Principle of Operation MAG-SM with Capacitive

Signal Measurements
The basis for the operation of electromagnetic flowmeters
are Faraday’s Laws of Induction. A voltage is induced in a The basis for the operation of electromagnetic flowmeters
conductor as it moves through a magnetic field. are Faraday’s Laws of Induction. A voltage is induced in a
conductor as it moves through a magnetic field.
This measurement principle is applied to a conductive
fluid which flows in a pipe through which a magnetic field is The voltage which is induced in the fluid is measured at two
generated perpendicular to the flow direction, electrodes located diametrically opposite to each other. The
see Electromagnetic Flowmeter Schematic. voltage is measured capacitively, i.e., the electrodes do not
come in contact with the fluid.
UE ~ B ⋅ D ⋅ v
Each electrode forms a coupling capacitor with the inside
The voltage which is induced in the fluid is measured at two wall of the lined meter tube on which the flow signal potential
electrodes located diametrically opposite to each other. This exists whose dielectric is the liner material. The flowrate
flow signal voltage UE is proportional to the magnetic induction proportional measurement signal is fed to the input of an
B, the electrode spacing D and the average fluid velocity v. integrated preamplifier over this coupling capacitor.
Noting that the magnetic induction B and the electrode spacing This flow signal voltage UE is proportional to the magnetic
D are constant values indicates that a proportionality exists induction B, the electrode spacing D and the average fluid
between the flow signal voltage UE and the average flow velocity v.
velocity v. The equation for calculating the volume flowrate

Magnet Coil Magnet Coil

Meter Tube in Meter Tube in

Electrode Plane Electrode Plane

Measurement Electrode Measurement Electrode

UE = Flow signal voltage

B = Magnetic induction
D = Electrode spacing
v = Average flow velocity
qv = Volume flowrate
Flow Signal Voltage Flow Signal Voltage
2
D π-
*) qv = ----------- ⋅v
4
Fig. 1 Electromagnetic Flowmeter Schematic

3
Flowmeter Primary, Model DS21_/DS4_F
4. Assembly and Installation
4.1 Inspection
Before installing the electromagnetic flowmeter primary check
for mechanical damage due to possible mishandling during
shipping. All claims for damage are to be made promptly to the
shipper prior to installation.

4.2 Installation Requirements Flowmeter

Primary
The flowmeter primary and the signal cables should not be
installed in close proximity to strong electromagnetic fields.
The flowmeter primary must be installed so that the meter tube
is always completely filled with fluid and cannot drain. A slight
upward slope of approx. 3% is desirable to prevent gas build up
within the flowmeter (Fig. 2 ).

Fig. 3

In horizontal installations the imaginary line connecting the

electrodes should be horizontal so that air or gas bubbles
cannot affect the flow signal voltage. This electrode orientation
is shown in Fig. 4 .

Electrode Axis

3°

Fig. 2

Vertical installations are ideal when the fluid flows in

an upward direction. Installations in drop lines, i.e., the fluid
flows from the top to the bottom are to be avoided because
Fig. 4
experience has shown that it is not possible to guarantee that
the pipeline will always remain 100% full and that an equilibrium
condition between the upward flowing gas and the downward For a free flow in- or outlet an invert should be provided
flowing fluid will not occur. to assure that the flowmeter primary is always filled with fluid
(Fig. 5 ).
Generally, the flowmeter primary should be installed in the pipe-
line with the cable connectors pointing downward. If the flow di-
rection with this arrangement does not agree with the flow
direction indicated by the arrow on the flowmeter primary, the
procedures described in Section Preliminary Checks should be
employed.

! Comments
The figures for the EMF flanged designs shown in
Section Installation Requirements Flowmeter Primary also
apply to the other process connection types e.g. Wafer
Design, aseptic connections, 1/8“sanitary connections,
hose connectors, Tri-Clamp, screwed flanges and others.

Fig. 5

4
 Flowmeter Primary, Model DS21_/DS4_F
In a free flow outlet (drop line) the flowmeter primary should be For heavily contaminated fluids a bypass line as shown in Fig.
not be installed at the highest point or in the discharge of the 8 , Design A is recommended, so that the flowmeter may be
pipeline (meter tube could drain, air bubbles, Fig. 6 ). mechanically cleaned without shutting down the process.

A A

B B
Fig. 6

The measurement principle is independent of flow profile as

long as standing eddies do not extend into the measurement
section (e.g. after double elbows, tangential inflows or half open
valves upstream of the flowmeter primary). In such situations, Fig. 8
measures to condition the flow are required. Experience
indicates that in most cases a straight upstream section with a
length of 3 x D and a downstream section of 2 x D is sufficient
(D = flowmeter primary size Fig. 7 ). The reference conditions When it is anticipated that the electrodes may become coated
for test stands, per DIN 19200, require a straight upstream with an insulating layer, a bypass line as shown in Fig. 8 ,
length of 10 x D and a 5 x D straight length downstream. For Design B, should be installed. For flowmeter primaries installed
Volume Flow Integrators additional installation requirements in the vicinity of pumps or other vibrating equipment the
are mandatory. See Installation of the Certified Designs Section utilization of mechanical dampers is advantageous (Fig. 9 ).
4.2.5 on Page 9.

Fig. 7
Fig. 9

Wafer valves are to be installed in such a manner that the

wafer, when open, does not extend into the flowmeter. Valves
or other shut off devices should be installed downstream so that
the flowmeter primary cannot drain.
An automatic empty pipe detector option is available in the
converter which uses the existing electrodes for its input.

5
Flowmeter Primary, Model DS21_/DS4_F
4.2.1 Installation of the Flowmeter Primary Wafer Design flowmeter primaries with are shipped without
The electromagnetic flowmeter can be installed at any arbitrary gaskets. The installation (axisymmetric and parallel) is made
location in the pipeline as long as the installation requirements directly into the pipeline without gaskets. Only when a ground-
(Page 4) are satisfied. Installation dimensions may be found in ing plate is installed is an additional gasket required (grounding
the appropriate Specification Sheet. At the same time, care plate / pipeline flange). See Table 3 for torque specifications.
should be exercised when selecting the installation site to For all other flanged flowmeter primary designs commercially
assure that moisture cannot enter into the connection area. available gaskets are to used made of materials compatible
Exercise care to assure that the housing cover gaskets are with the fluid being metered and suitable for the operating
correctly seated when installing the covers after the installation temperatures (rubber, It, PTFE, etc.). See Tables 2 and 3 for
and start-up have been completed. torque specifications.

! Note:
Electrode Axis
For installations in horizontal pipelines make sure that neither
Graphite should not be used to lubricate the flange or
electrode is located at the highest point. Any gas or air bubbles
process connection gaskets because an electrically
which may be present in the fluid could interrupt the electrical
conductive coating could form on the inside surface of the
connection between the electrodes and the fluid. The ideal
meter tube adversely affecting operation.
installation conditions for an EMF are assured in a vertical
The flowmeter primary should not be installed in close
installation. The preferred orientations are shown in Fig. 10 .
proximity to strong electromagnetic fields. Steel parts (e.g.
Gaskets mounting brackets should be spaced at least 100 mm
distant from the flowmeter primary). Vacuum shocks should
It is essential to use the gaskets which are included with the
be avoided to prevent damage to the liner.
flowmeter primary shipment. Only when these gaskets are
used and the flowmeter primary has been installed correctly Comment:
can leaks be avoided. Observe the information in Table 1. A vacuum resistant liner is available in the program.

FILL-MAG Flowmeter Primary Installation Any valves or relays used in the system should incorporate
appropriate measures to reduce interference signals such as
Generally, the flowmeter primary should be installed in the protection diodes, varistors or R-C combinations (VDE 0580)
pipeline with the cable connectors pointing downward.
If the flow direction with this arrangement does not agree with
the flow direction indicated by the arrow on the flowmeter
primary the following procedure can be employed so that the
contact outputs respond correctly for reverse flow conditions.
Steps to reverse the direction indication:
a) For a Standard- and Ex-flowmeter primaries the shielded signal
leads (only at the primary) are to be interchanged.
Interchange terminal 1 with terminal 2.
Interchange terminal 1S with terminal 2S.
Electrode Axis
b) For flowmeter primaries with preamplifiers only terminals
1 and 2 (at the flowmeter primary) are to be interchanged
because terminals 1S and 2S are used for the preamplifier
supply voltage U+ and U- of ±12 V DC.

Control, Signal and Supply Voltage Cables

! Note:
The flowmeter primary should not be installed in
close proximity to strong electromagnetic fields. It is
recommended that the control-, signal- and supply
power cables be routed separate from one another. It is
advantageous to install the cables in grounded metal Electrode Axis
conduits. Multiple cables of the same type may be Horizontal Vertical
Installations Installations
installed in the same conduit.

Fig. 10

6
 Flowmeter Primary, Model DS21_/DS4_F
Gasket Surfaces on the Mating Flanges Torque Specifications
In all installations parallel mating flange surfaces should be Liner Meter Size Process Bolts Torque PN
provided and suitable gaskets used. Only then can leaks be Inch DN Connection Max. NM bar
avoided. The flange gaskets for the flowmeter primary must be PFA/ 1/10-3/8 3-10 Flanges, 4 x M12 8 40
installed concentrically to achieve optimum measurement PTFE/ 1/2 15 Wafer 4 x M12 10 40
results. The parallel gasket surface requirements for the Hard 3/4 20 Design 4 x M12 16 40
mating flanges are: Rubber 1 25 4 x M12 21 40
(≥ 1/2”: 1-1/4 32 4 x M16 34 40
DN 15) 1-1/2 40 4 x M16 43 40
ETFE 2 50 4 x M16 56 40
(≥ 1”: 2-1/2 65 8 x M16 39 40
∅ Outside DN 25) 3 80 8 x M16 49 40
Parallel Gasket PFA 4 100 Flanges 8 x M16 47 16
∅ Inside ≥ 10”: 5 125 Wafer 8 x M16 62 16
Surfaces
DN 250 6 150 Design, 8 x M20 83 16
PTFE/ 8 200 ≤4”:DN100 12 x M20 81 16
Hard Rbr 10 250 12 x M24 120 16
Flowmeter Primary Required Parallel Gasket Surface ETFE 12 300 12 x M24 160 16
Inch DN ∅ Inside mm ∅ Outside mm ≤ 12”: 14 350 16 x M24 195 16
DN 300 16 400 16 x M27 250 16
1/10 – 1/4 3 – 6 8 21.5
3/8 10 14 35 PTFE 20 500 Flanges 20 x M24 200 10
1/2 15 18 35 ≥ 32”: 24 600 20 x M27 260 10
3/4 20 22 44 DN 800 28 700 24 x M27 300 10
1 25 29 52 Hard 32 800 24 x M30 390 10
1-1/4 32 37 61 Rubber 36 900 28 x M30 385 10
1-1/2 40 43 71 40 1000 28 x M33 480 10
2 50 52 91 48 1200 32 x M36 640 10
2-1/2 65 71 107 54 1400 36 x M39 750 10
3 80 81 124 64 1600 40 x M45 1050 10
4 100 100 149 72 1800 44 x M45 1100 10
78 2000 48 x M45 1200 10
Table 1
Hard 48 1200 Flanges 32 x M30 365 6
Protection Plates Rubber 54 1400 36 x M33 480 6
64 1600 40 x M33 500 6
The protection plates for the PTFE/PFA/ETFE lined flowmeter
72 1800 44 x M36 620 6
primaries have been installed to prevent damage to the liner 78 2000 48 x M39 725 6
during shipment. Remove these protection plates only when
Table 2
ready to install the meter in the pipeline. Be careful not to cut or
otherwise damage the liner in order to prevent leakage. The Max. Torque Values for PTFE-Envelope Gaskets
Dimension Drawings for your instrument design may be found
Liner Meter Size Process Bolts Torque PN
in the Specification Sheet.
Inch DN Connection Max. NM bar
Torque Specifications for Flanges PFA 1/10-5/16 3-8 Wafer Design 4 x M12 2.3 40
Variable
The mounting bolts are to be tightened equally in the
Connections
usual manner without excessive one-sided tightening. We
3/8 10 4 x M12 7.0 40
recommend that the bolts be greased prior to tightening and 1/2 15 4 x M12 7.0 40
that they be tightened using a wrench with a normal length, in 3/4 20 4 x M12 11.0 40
a crisscross pattern as shown in Fig. 11 . Tighten the bolts 1 25 4 x M12 15.0 40
during the first pass to approx. 50%, during the second pass to Variable
1-1/4 32 4 x M16 26.0 40
approx. 80% and only during the third pass to 100% of the max. PFA Connections
1-1/2 40 4 x M16 33.0 40
torque value. The max. torque values should not be exceeded, Wafer Design
2 50 4 x M16 46.0 40
see the following tables. 2-1/2 65 8 x M16 30.0 40
3 80 8 x M16 40.0 40
4 100 8 x M20 67.0 40
Table 3

Fig. 11

7
Flowmeter Primary, Model DS21_/DS4_F
4.2.2 Installations for Protection Class IP 68 4.2.4 Installation in Larger Size Pipelines
For flowmeter primaries for Protection Class IP 68 the The flowmeter can readily be installed in larger size pipelines
maximum permanent submerged depth is 5 m. In place of through utilization of flanged transition sections (e.g. Flanged
the standard cable connectors, hose enclosed Pg-cable Reducers per DIN 28545).The pressure drop resulting from the
connectors are utilized. The cable is installed inside a 1/2” hose reduction can be determined from Diagram Fig. 14 using the
from connection box to the maximum water surface height. following procedure:
Above this level the cable is installed in a watertight cable
1. Calculate the diameter ratio d/D.
connector included with the shipment. The 1/2” hose is then
sealed and secured to the hose connectors using threaded 2. Calculate the flow velocity as a function of the meter size
hose clamps. After the installation has been completed the and the flowrate:
connection box cover must be carefully reinstalled. Q (Instantaneous Flowrate)
v = -------------------------------------------------------------------------
Primary Constant
Signal cable or magnetic field supply cable The flow velocity can also be determined from the Flow
Watertight cable connector Rate Nomograph.
1/2“-Hose extends above max. water level
for enclosing the signal cable and magnetic field
supply cable. Seal hose to the cable connectors.
3. The pressure drop can be read on the -Y- axis at the
intersection of the flow velocity value and the "Diameter
Ratio d/D" value on -X- axis in Fig. 14
Max. Submergence Depth 5m

d = EMF Inside diameter

D = Pipeline inside diameter
v = Flow velocity in m/s
∆p = Pressure drop in mbar
Fig. 12 Installation IP 68 (Hose Connections)
Pressure Drop Diagram for EMF
Flanged Reducers with α/2 = 8°
4.2.3 Installation of the High Temperature Design
Please see the Installation Notes in Sections 4.2 and 4.2.1 .
The connection box in the high temperature design for fluid
temperatures <180 °C, is spaced away from the lower section
of the flowmeter primary by a pipe nipple. This provides thermal
insulation between the connection box and the lower section of
the flowmeter primary. The insulation for the pipeline and the
flowmeter primary should be installed as shown in Fig. 13 .
Pressure Drop ∆p [mbar]

Diameter Ratio d/D

Fig. 13 Insulated Pipeline
Fig. 14 Pressure Drop Nomograph

8
 Flowmeter Primary, Model DS21_/DS4_F
4.2.5 Installation of the Certified Designs
Essentially the installation requirements described in the
Section Installation Requirements Flowmeter Primary also
! Note:
The flow ranges are to be selected as prescribed in the
above tables. Subsequent flow range changes require a
apply to the flowmeters certified for custody transfer. There
recalibration on a certified test stand.
are some additional requirements which must be observed that
are listed in the Certification for Electromagnetic Volume Flow Please specify the desired flow range in your order based
Integrators certified for intrastate custody transfer. on the specification in the above tables. Consideration
should be given to the maximum flowrate for the particular
The instrument design “Electromagnetic Volume Flow
size as well as to the prescribed flow range steps.
Integrator with Electrical Counter” has been approved by the
Physikalisch-Technischen Bundesanstalt [National Institute of Example: 1” : DN 25; minimum selectable flow range Qmax
Science and Technology] in Braunschweig, Germany for = 60 l/min; any flow range can be set between 60 l/min and
intrastate custody transfer. For the Volume Flow Integrator 200 l/min in steps of 10 l/min.
MAG-SM, consisting of a flowmeter primary and a converter,
the following approvals have been granted. Calibration
The calibrations of the Electromagnetic Volume Flow Integrator
5.721 Electromagnetic Volume Flow Integrator are carried out in the ABB test stands in Goettingen, Germany
86.02 with Electrical Counter for filling Beer Kegs which have been approved for certified calibrations. After the
calibration has been completed those parameters which impact
5.721 Electromagnetic Volume Flow Integrator the certification may only be changed in the presence of a
87.05 with Electrical Counter for Liquids, other than Certification Official.
Water (Milk, Beverage Concentrates or Syrups,
Beer, Wort, Brine). The approval also applies to Accessories
chemical liquids. Additional instruments such as volume flowrate indicators,
recorders or controllers as well as approved printers, flow
For the Electromagnetic Volume Flow Integrators with controllers or remote totalizers may be connected to the
Electrical Counters with approval 5.721/87.05 Liquids other Volume Flow Integrator.
than Water, the Certification Regulation (EO) of 15 Jan. 1975 Printers, flow controllers and remote totalizers, when required,
also applies, which was subsequently revised by the 6th must be connected to the Volume Flow Integrator during its
Revision to the Certification Regulation of 08 Mar 1985 calibration.
(BGBI IS.568), and specifically the “General Requirements“
(EO AV) with Appendix 5 (EO 5) “Measurement Instruments for Installation Requirements
Determining the Volume or Mass of Flowing Fluids other than Up- and downstream of the flowmeter primary straight pipe
Water“, Section 2, Part 1. sections are to be installed with the same inside diameter as the
inlet opening of the flowmeter. Upstream of the flowmeter
Approved Flowmeter Sizes for “Liquids other than
primary the length must be at least 10 times the diameter of the
Water“
flowmeter primary and the downstream length must be at least
Flowmeter Sizes and Maximum Approved Flowrates 5 times the diameter of the flowmeter primary, see Fig. 15 .
Inch DN Qmax Liter/min.
The flowmeter primary must always be completely filled with
1 25 selectable from 60 to 200 in steps of 10
1-1/4 32 selectable from 100 to 400 in steps of 10
fluid.
1-1/2 40 selectable from 150 to 750 in steps of 50 The distance (signal cable length) between the flowmeter
2 50 selectable from 250 to 1000 in steps of 50 primary and the converter may not exceed 50 m.
2-1/2 65 selectable from 400 to 2000 in steps of 100
3 80 selectable from 700 to 3000 in steps of 100
4 100 selectable from 900 to 4500 in steps of 100
6 150 selectable from 2000 to 10000 in steps of 500

Meter Size Minimum Metered Fluids

Flowrates Liquids other than Water, also
Inch DN Liter/min. Chemical Liquids - Examples:
1 25 2 Milk, Beverage Concentrate
20 Beer
1-1/4 32 5 Beer, Milk 5 x DN (10 x DN) 2 x DN (5 x DN)
1-1/2 40 20 Beer, Milk
2 x DN (10 x DN)
2 50 200 Beer, Wort
for forward and
2-1/2 65 500 Beer, Wort, Milk reverse flow metering
3 80 500 Beer, Wort, Milk
4 100 2000 Wort, Brine Fig. 15
6 150 2000 Brine

Min. flow range 2.5 m/s. Max. Flow Range10 m/s.

9
Flowmeter Primary, Model DS21_/DS4_F

KEG-Filling with the FILL-MAG System

Four keg sizes with their corresponding beer volumes
can be entered and selected using the external contacts
(e.g. optical beer keg size recognition). The corresponding
anticipatory contact can also be individually set. The
automatic overflow correction continuously reflects the
current operating conditions.
When underfills occur the Fill-MAG checks if the fill volume
is within the certified error limits and announces the error.
The same applies to overfills. The coupling of the control
technology and the integration of the Fill-MAG in the fill
system is accomplished in cooperation with the equipment
manufacturer.

Contact Outputs
Anticipatory Contact
E.g. 27 Liter (for 30 I KEG)
E.g. 47 Liter (for 50 I KEG)
End Contact
E.g. 30 Liter
E.g. 50 Liter
Control Inputs

! Note :
To provide galvanic isolation the control inputs are
designed as optocoupler inputs. The various input
functions require a 24 V DC voltage supply which is to
be provided by the customer.
Fill (Batch) Start (Terminals G2, 68)
The fill or batch cycle is initiated by an ext. Start pulse
(e.g. from a SPC).
Fill (Batch) Stop (Terminals G2, 69)
The fill or batch cycle is terminated by an ext. Stop contact.
External Fill Volume Selection (Terminals G2, A1,A2)
a) from a switch
b) from a keg size recognition device1)

1) For ext. keg size recognition a separate override switch must be included
for filling a Certified-KEG (30 Liter), because its size is equivalent to a 50 Liter
KEG.

10
 Flowmeter Primary, Model DS21_/DS4_F
4.3 Replaceable Parts List, Connection Box, Aluminum Housing ≤ 12” / DN 300

3
2 1.1
2.1

4
4.1
4.2

9 8 6
9.1 6.1
9.2 6.2
Item No. Description Part No.
1 Connection board, standard 3/4” - 12” : DN 20 - 300 D685 A869U01
Connection board, standard 1/10” - 1/2” : DN 3 - 15 D685 A869U03
1.1 Connection board, preamplifier 3/4” - 12” : DN 20 - 300 D685 A868U03
Connection board, preamplifier 1/10” - 1/2” : DN 3 - 15 D685 A868U05
2 Sheet metal screw 2.9 x 6.5 DIN 7981 D055E106CZ01
2.1 Serrated washer A 3.2 DIN 6798 D085G017AU32
3 Slotted cheese head screw M§ x 8 DIN 84 D002F107AU20
4 Lower section with cable connector M20 x 1.5 D612A153U01
4.1 Lower section with cable connector Pg 13.5 D612A153U02
4.2 Lower section with cable connector, hose Pg 13.5 and IP 68 D612A153U18
5 Cover complete. D612A152U01
6 Cap screw, hex socket head M 4 x 18 DIN 912 D009G113AU20
6.1 Flat washer B 4.3 DIN 125 D085A021BU20
6.2 Security ring D160A001U25
7 Cover gasket D333F022U01
8 Ground accessories D614L607U01
9 Cable connector M20 x 1.5 D150A008U15
9.1 Cable connector Pg 13.5 D150A008U02
9.2 Cable connector, hose Pg 13.5 and IP 68 D150A006U02
9.2.1 Hose nipple IP 68 Stn Stl D365A027U01
9.2.2 Screw hose clamp SGL 12 - 20 Stn Stl 1D108D1016
9.2.3 PE - hose 5/8“ 16 x 13 mm, black UV-resistant D109A001U07
9.2.4 Hose nipple IP 68 Stn Stl for the Pg at the end of the cable D365A020U01

9.2 9.2.4 9.2.2 9.2.3 9.2.1 9.2

Fig. 16

11
Flowmeter Primary, Model DS21_/DS4_F
4.4 Replaceable Parts List, Connection Box, Aluminum, Flowmeter Primary 14” - 16” : DN 350 - 400

11,12

10

13, 14

7
6
4 5 3 8 9,10
6

Item No. Description Part No.

1 Lower section D323D550U01
2 Center section D674A613U02
3 O-Ring D101A019U01
4 Interconnection Diagram D338C499U01
5 Cover D612A126U02
6 Cable connector D150A008U02
7 Cable connector D150A008U08
8 Cover plate D351A025U01
9 Spring washer M4.0 DIN 137 D085D020AU20
10 Slotted cheese head screw M4.0 x 6 DIN 84 D002G106AU20
11 Lock washer M6.0 x DIN 7980 D085L026ZU20
12 Cap screw, hex socket head M6.0 x 30 DIN 912 D009J118AU20
13 Lock washer M 6.0 DIN 7980 D085L026ZU20
14 Slotted cheese head screw M6.0 x 25 DIN 7964 D024J116AU20

Fig. 17

12
 Flowmeter Primary, Model DS21_/DS4_F
4.5 Replaceable Parts List, Connection Box, Aluminum, Flowmeter Primary ≥ 20” : DN 500

11,12

10

13,14
15,16

9,10

8
6 7
4 5 3

2 6,7

Item No. Description Part No.

1 Lower section D323D550U01
2 Center section D674A613U02
3 O-Ring D101A019U01
4 Interconnection Diagram D338C499U01
5 Cover D612A126U02
6 Cable connector D150A008U02
7 Cable connector D150A008U08
8 Cover plate D351A025U01
9 Spring washer M4.0 DIN 137 D085D020AU20
10 Slotted cheese head screw M4.0 x 6 DIN 84 D002G106AU20
11 Lock washer M 6.0 x DIN 7980 D085L026ZU20
12 Cap screw, hex socket head M6.0 x 30 DIN 912 D009J118AU20
13 Lock washer M6.0 DIN 7980 D085L026ZU20
14 Slotted cheese head screw M6.0 x 25 DIN 7964 D024J116AU20
15 (230 V) Fuse 5 x 20 MM 0.160 A-slow blow D151B001U09
16 (230 V) Fuse identification tag 1D338C1201
15 (115 V) Fuse 5 x 20 MM 0.315 A-slow blow D151B001U01
16 (115 V) Fuse identification tag 1D338C1195

Fig. 18

13
Flowmeter Primary, Model DS21_/DS4_F
4.6 Replaceable Parts, Flowmeter Primary
When repairs to the liner, electrodes or magnet coils are
required, the flowmeter primary must be returned to the
ABB Factory in Göttingen, Germany. Please note the
information in the “Introductory Safety Notes for the EMF
System”

1 1
4/5

2
3

8/9
10

11

Standard Preamplifier
Fig. 19 Connection Box, Stainless Steel

Replaceable Parts, Connection Box, Stainless Steel Flowmeter Primary ≤ 4” : DN100

Item No. Description Part No.
1 Connection board standard D685A869U01
1 Connection board with preamplifier D685A698U03
2 Lower section SS 304 / No. 1.4301
Models 10DS2111/2112, DS21_ D612A128U01
Model 10DS3112 1/10” - 1/2” : DN 3-15 D612A128U03
Model 10DS3112 /34” - 1-1/2” : DN 20-40 D612A128U04
Model 10DS3111 D612A128U05
3 Gasket (conductive) D333F016U01
4 Phillister head screw M3 x 6 DIN 7985 D004F106AU20
5 Serrated washer A3.2 DIN 6798 D085G017AU32
6 Connection thread gasket ring PE Pg 13.5 D150Z007U06
7 Cable connector Pg 13.5 plastic gray D150A008U02
8 Spacer D375A018U01
9 Machine screw, hex hd M4 x 14 DIN 7964 SS D024G110AU20
10 Washer “Nyltite-Siegel“ F.M4 D115B004U01
11 Cover SS 304 / No. 1.4301 D612A127U01
12 Interconnection Diagram Std. D338D293U01

IP 68 design upon request

14
 Flowmeter Primary, Model DS21_/DS4_F
4.7 Replaceable Parts List with Preamplifier
Flowmeter primary for metering fluids with a conductivity from 0.5 µS/cm.

10, 11 10, 11

4,12 3
5
2
6

7 8/9

Fig. 20 Connection Box and Electronic Area

Replaceable Parts

Item No. Description Part No.

1 Lower section with connection box D612A111U01
2 O-Ring D101A009U01
3 Cover, large D612A182U01
4 Cover, small D379D024U02
5 Gasket D333F004U01
6 Cable connector M20 x 1.5 D150A008U15
7 Preamplifier board D685A442U02
8 Preamplifier input D685A859U03
9 Cover D379B037U01
10 Hex head screw M6 x 16 DIN 33 Stn Stl D022J112AU20
11 Spring washer DIN 137 Stn Stl D085D026AU20
12 Interconnection Diagram D338C330U01

15
Flowmeter Primary, Model DS21_/DS4_F
5. Safety Relevant Section of the
Instruction Bulletin
5.1 Electrical Connections Anschluss
5.1.1 Grounding
The grounding procedure described is to be observed.
According to VDE 0100, Part 540 a Cu-wire with a cross section
of at least 4 mm2 is to be connected between the ground screw
on the flowmeter primary (on the flange or the housing) and
ground. For measurement reasons the ground potential should
be identical to the pipeline potential if possible. An additional
ground connection at the terminals is not required.
When installed in plastic or lined insulating pipelines the Fig. 22 Flowmeter Primary 2” – 4” : DN 50 – 100, Wafer Design
connections to ground are made from a grounding plate or
grounding electrode. If there are stray potentials in the fluid the
installation of a grounding plate on both sides of the flowmeter
primary is recommended.
Three grounding procedures are described below. In cases a)
and b) the fluid is in electrical contact with the pipeline. In case
c) the fluid is insulated from the pipeline.

! Note:
The ground screw in flowmeter primaries Model DS21_ is
located on the lower section of the connection box. For in-
strument designs with aseptic connectors, Tri-Clamp and
hose connectors the meter tube is in electrical contact with
the fluid. It is only necessary to connect the ground connec-
tion on the flowmeter primary to ground, see Fig. 32 and
Fig. 33 .
Fig. 23 Flowmeter Primary 3/8”-12” : DN10 - 300,
Two Piece Housing and Flanged
a) Metal pipe with fixed flanges
1) Drill blind holes in the flanges on the pipeline
(18 mm deep).

2) Tap holes, (M6, 12 mm deep).

3 Attach the ground strap to the flange using a screw

(M6), spring washer and flat washer and connect to the
ground connection on the flowmeter primary.
4) Connect a 4 mm2 CU wire between the ground
connection on the flowmeter primary and a good ground.

Fig. 24 Flowmeter Primary from 14“ : DN 350,

Welded Steel Design

Fig. 21 Flowmeter Primary 1/10” – 1-1/2” : DN 3 – 40, Flanged

16
 Flowmeter Primary, Model DS21_/DS4_F
b) Metal Pipe with Loose Flanges c) Plastic, Concrete or Pipelines with
1) In order to assure a trouble free ground connection to Insulating Liners
the fluid and the flowmeter primary in a pipeline with 1) Install EMF in pipeline with a grounding plate.
loose flanges, M6 threaded studs should be welded to
directly to the pipeline. 2) Connect the connection tab on the grounding plate to
2) Attach the ground strap to the flange using a nut, spring the ground connection on the flowmeter primary with
washer and flat washer and connect to the ground the ground strap.
connection on the flowmeter primary.
3) Connect a 4.0 mm2 CU wire between the ground 3) Connect a 4.0 mm2 CU wire between the ground
connection on the flowmeter primary and a good ground. connection on the flowmeter primary and a good ground.

Grounding Plate

Fig. 25 Flowmeter Primary 1/10” - 1-1/2” : DN 3 - 40, Fig. 28 Flowmeter Primary 1/10” – 1-1/2” :DN 3 – 40, Flanged
Screwed Flanges

Grounding Plate

Fig. 26 Flowmeter Primary 2” – 4” : DN 50 – 100, Wafer Design Fig. 29 Flowmeter Primary 2” – 4” : DN 50 – 100, Wafer Design

Grounding Plate

Fig. 27 Flowmeter Primary 3/8” – 12” : DN 10 – 300, Fig. 30 Flowmeter Primary 3/8” – 12” : DN 10 – 300,
Two Piece Housing and Flanges Two Piece Housing and Flanged

17
Flowmeter Primary, Model DS21_/DS4_F
5.1.4 Power Consumption
The values for the supply voltage and current are specified on
the instrument tag on the flowmeter primary. The cable cross
section and the fuse rating must be compatible (VDE 0100).
The power is ≤ 30 VA (flowmeter primary including the convert-
er).

Fig. 32 Flowmeter Primary 1/10” - 4” :DN 3 -100,

Aseptic Pipe Connections

Fig. 33 Flowmeter Primary 1/10”- 2-1/2” : DN 3- 65,

Tri-Clamp Connections

5.1.2 Supply Power Connections

The supply power is connected in accord with the specifications
on the Instrument Tag to terminals L (phase) and N (Neutral),
L+ and L-, or 1L1 and 1L2 at the flowmeter converter over a
main fuse and a main switch.
The Electromagnetic Flowmeter Primary is connected to
the converter using a signal/reference voltage and a supply
cable. For detailed interconnection cabling information see
the appropriate Instruction Bulletin for the converter.

5.1.3 Magnet Coil Supply

The type of supply power to the magnet coils is a function
of the size of the flowmeter primary. The appropriate
Interconnection Diagram should be used!

Flowmeter Primary 1/25” to 16” : DN 1 to 400:

The supply power for the magnet coils is provided by the con-
verter directly over terminals M1, M3 with a cable, e.g. shielded
2 x 1.5 mm2 .
Flowmeter Primary 20” to 40” : DN 500 to 1000:
The magnet coils are supplied directly from the line and
not from the converter. It is essential that both the flowmeter
primary and the converter be supplied from the same main
fuse and main switch.

18
 Flowmeter Primary, Model DS21_/DS4_F
5.1.5 Signal Cable Connections

!
1
Warning:
2
The signal cable connections vary with the size of the
flowmeter primary. The appropriate Interconnection
Diagram should be used!

The signal cable conducts signals of only a few millivolts and 3

should therefore be installed using the shortest path. The
cables should not be routed in the vicinity of large electrical 4
machinery or switch gear equipment which could induce stray
fields, pulses and voltages. The signal cable should not be fed 5
through branch fittings or terminals strips.
6
The maximum allowable signal cable length is 50 m for designs
without a preamplifier, Ex-Instruments and certified Volume 7
Flow Integrators. If a preamplifier is installed in the flowmeter
primary for low conductivity metering, the maximum signal
cable length limit is increased to 200m. A shielded reference
voltage cable is located parallel to the signal leads in the cable
assembly so that only two cables (a signal/reference voltage
cable and a supply cable for the magnet coils) are required 1 PVC jacket, white 5 Reference voltage jacket, white
2 Woven steel wire, 6 1x each shielded, woven Cu wire,
between the flowmeter primary and the converter. The signal natural φ 0.15 mm natural φ 0.1 mm
cable is designed with a woven copper shield (common 2 Woven copper wire, 7 Polyethylene, natural
natural φ 0.13 mm
potential) which surrounds the individually shielded signal leads 4 Electrode flow signal
and the shielded reference voltage leads. The signal lead φ 0.75 mm (red and blue)
shields serve as “Driven Shields” for the flow signal
transmission. Fig. 34 Signal Cable Construction D173D018U02

To shield against magnetic pickup the cable incorporates an

outer steel shield which is to be connected to the SE Terminals.
! Note:

! Note: The shields of the signal leads may not contact each other
or the outer shield (signal short circuit).
If plant conditions make it impossible to avoid proximity
to electrical machinery or switch gear equipment, it is 5.1.6 Interconnection Diagram
advisable to install the signal cable in a grounded metallic
conduit.
Converter
The preamplifiers in the flowmeter primaries, when this
option are supplied with a DC voltage at terminals
U- and U+.
The signal-/reference voltage cable connections at the
flowmeter primary and converter are to be made in accordance
with the appropriate Interconnection Diagram. If the actual flow
direction does not agree with the flow direction arrow on the
flowmeter primary connections at terminals 1 and 1S must 14” - 16”
DN 350-400
be interchanged with 2 and 2S at one end of the cable. In 3/8” - 4”
flowmeter primaries with preamplifiers only terminals 1 and 2 DN 10-300
20” - 40”
should be interchanged. DN 500-1000

1/12” - 5/16”
The potential on terminal 3 is at the common of the flowmeter DN 1-8 aund

primary and is connected to ground or PA per VDE 0100/VDE 5 µS/cm/0.5 µS/cm

Flowmeter Primary
0160.
1) Shielded Signal Cable
Part No. D173D018U02
2) Excitation Cable e.g. shielded
2 x 1.5 mm2, terminals M1, M3
3) Voltage supply for preamplifier
1/25” - 5/16” : DN 1 - 8 standard and ≥ 3/8” : DN 10

19
Flowmeter Primary, Model DS21_/DS4_F
5.1.7 Connection Area
The signal cable leads should be installed using the shortest
path to the connection terminals. Loops are to be avoided,
(see Fig. 37 and Fig. 38 ).

Standard Flowmeter Primary

Connection Box with Screwless Spring Loaded
Terminals
Operation: Lead (2), with the insulation stripped, can be
inserted into the terminal when spring (1) is depressed.
Release the pressure (3) on the spring (Fig. 35 ).

Signal Cable Magnet Excitation Cable

(e.g. shielded 2x1.5 mm2)
Flowmeter Primary with Preamplifier

Fig. 35 Cable Insertion in the Screwless Spring Loaded Terminals

When replacing and tightening the cover care should be

exercised. Check that the gasket is properly seated. Only
then will Protection Class IP 67 be assured.

! Note:
When installing the signal/excitation cable to the flowmeter
primary a water trap should be provided, (Fig. 36 ).

Magnet Excitation Cable

Signal Cable (e.g. shielded 2x1.5 mm2)

Terminal Designation Connection

1+2 Electrode flow signal leads (red and blue)
1S, 2S Signal lead shields
U+/U- Voltage supply for preamplifier over
signal cable shields
16 Reference voltage lead (white)
3A Reference voltage lead shield
3 Inner cable shield (copper)
Common potential
SE Outer shield (steel)
Fig. 36 Cable Installation M1 + M3 Connections for magnetic field excitation
(from converter)
Fig. 37 Connection Area for Flowmeter Primaries ≤ 12”:DN 300

20
 Flowmeter Primary, Model DS21_/DS4_F

≥ 20” : DN 500 *) < 20” : DN 500

Flowmeter Primary with Preamplifier

Terminal Designation Connection

1+2 Electrode flow signal leads
1S + 2S (U+/U-) Electrode flow signal lead shields ( ) voltage supply for preamplifier
16 Reference voltage lead
3a Reference voltage lead shield
3 Inner shield (copper) common potential
M1 + M3 Connections for magnetic field excitation (from converter)
*) L + N for ≥ 20”:DN 500 supply power see Instrument Tag
M2 + B Test point
Fig. 38 Connection Box Flowmeter Primary

21
Flowmeter Primary, Model DS21_/DS4_F
6. Start-Up 6.3 Maintenance
The start-up procedure of the EMF system can be initiated after The flowmeter primary is essentially maintenance free. The
the installation of the flowmeter primary and converter have ambient conditions (air circulation, humidity), seal integrity of
been completed. A preliminary check of the flowmeter primary the process connections, cable connectors and cover screws,
should be made. Checking of the flowmeter primary with the functional reliability of the supply voltage, lightning protection
converter is described in Section 7. Testing and Error Search of and the grounds should be checked annually.
the Flowmeter Primary Using the Converter*).
The electrodes should be cleaned if the flow indicated by the
6.1 Preliminary Checks converter changes even though the flowrate has not. Higher
flow indications are due to insulating coatings while decreases
Check to assure that in the indications are due to conductive coatings.

! Note:
• the flow direction of the fluid agrees with the direction
indicators in the display.
• the installation requirements in Section 4.2 have been Repairs or maintenance tasks should only be performed by
considered. qualified personnel.
• the cable connections agree with the Interconnection See the note (Hazardous Material Information), if the
Diagram. flowmeter primary is to be returned to the ABB Factory in
• the ambient conditions do not exceed the specified limits. Göttingen, Germany!
• the ground connections agree with the specifications in
5.1.1 .
• the configured parameters agree wiht the operating
conditions.
• the system zero software adjustment was completed, (see
Section 6.2 Zero Check).
• that the parameters Flowmeter Primary Model and
Operating Mode are correctly entered in the converter.

! General Information:
If the flow direction indicators in the display do not agree
with the actual flow directions it may be because the
signal lead connections were interchanged. Interchange
the connections at terminals 1 with 2 and 1S with 2S at the
flowmeter primary.
For the designs with a preamplifier only connections at
terminals 1 and 2 should be interchanged.
The coordination between the flow direction and the
direction indicators in the display can also be reversed
in the parameter “Flow Direction” by selecting “Normal
or Inverse”.

6.2 Zero Check

During start-up or when checking the system the System Zero
is to be set in the conveter after the warm up phase has been
completed. The fluid in the flowmeter primary must be at an
absolute standstill and the meter tube must be completely filled
with fluid. The parameter “System Zero” in the converter can
then utilized to manually set or automatically adjust the zero.
Select the parameter using ENTER and with the arrow keys
select either “automatic” or “manual” and accept by pressing
ENTER. During an automatic adjustment the converter counts
in the second display line from 0 to 256 seven times, after which
the automatic zero adjustmnet is completed. The adjustment
procedure takes approx. 20 seconds and the resultant value
should be within the range of ±1500 Hz.

22
 Flowmeter Primary, Model DS21_/DS4_F

7. Testing and Error Search of the Flowmeter Primary Using the Converter*)
Warning
When the housing cover is removed the
EMC and Personnel Contact protection
is voided.

Connections agree with the Interconnection Diagram? Was the no Check the complete measurement system. See the Instruction
total measurement system checked? Bulletin for the converter under “Error Search”.
yes
Connect an oscilloscope from 16 to 3 or from TP102 to TP1011). no Excitation voltage source defective. Break in the excitation
Is the AC voltage a few millivolts? (50-150 mVeff). Connect a cable. Calibration Unit defective. Fuse in converter housing
digital voltmeter on the AC range across terminals 16 and 3. Is blown. Unsolder the magnet coil leads (M1, M3). After the
the reference voltage approx. 50-150 mVrms? Check the voltage connection board has been removed the solder connections are
supply to the magnet coils, is the AC voltage approx. 60 Vrms. accessible. The insulation resistance to the housing must be
greater that 10 MOhm, otherwise short circuit to common.
yes
Disconnect the signal cable at the flowmeter primary. (Turn off no Electrodes are contaminated, conduct a CIP-Cleaning or
supply power). clean with normal cleaning fluids and water. Electrodes leak.
Measure the electrode resistance with an ac bridge under a Flowmeter primary must be returned to the factory for repair.
full pipe condition. 3) Are the measured values from electrode
1 to 3 and from electrode 2 to 3 the same within ± 5%.
yes
Disconnect signal cable. Turn on power. no Check grounds, max. noise voltage is exceeded.
Connect an oscilloscope across TP5 to TP1012). Is the mea-
sured voltage less than 70 mVrms at zero flowrate?
yes
Measure the reference voltage and the magnet coil current. no New calibration
These values are used to calculate the Calibration Factor
I Coil
- [S]
C = -----------
U Ref
ICoil is measured in series with the cable connected to M1 or M3
and URef across connection terminals 16-3A4) using a high
impedance digital AC multi meter. These connections are
located in the calibration unit of the flowmeter primary. Does the
calculated Calibration Factor agree with the value recorded in
the Calibration Report?
yes
Flowmeter primary operational.

*) Checks for 10DS3111, 10DI1425,

DS41 ≥ D20” : DN 500 upon request.
1) Test points are located on the analog board in the
converter.
2) TP5 is located on the preamplifier and integrator
module (see Fig. 39 ). TP101 is located on the
analog board.
3) Not used for flowmeter primaries with preamplifiers.
4) Test points see Page 20.

23
Flowmeter Primary, Model DS21_/DS4_F

Fig. 39 Preamplifier and Integrator Module

24
Rights reserved to make technical revisions.
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stracts - and in particular, duplicating, photocopying, electronic distribution or storing in data processing installations or networks
without the express consent of the copyright holder is strictly forbidden and may lead to civil and criminal proceedings.

ABB Automation Products GmbH Rights reserved to make technical revisions

Printed in the Fed. R. of Germany
Dransfelder Str.2 D184B064U02 Rev. 03
D37079 Göttingen, Germany Issued 08.02
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