!

"" SERVICE AID

Implement at next service.
Recall instruments. No. SA 09/01 Date: April 2005
Product AquaMaster
Implement On all Battery Units version Manual N/A

Information only.

AquaMaster Service Check Sheet

Site Name Account Number/Site Reference
Engineer (Please Print name) Visit date.

Apparent fault:

The external testing of the coil is possible using

a. Digital meter to measure the coil resistance
b. Megger to measure the isolation.

When using these instruments on the sensor cable make sure that the transmitter is
disconnected from the electronic display unit [transmitter].

Transmitter Disconnected From Sensor

Table of Measurement Meter used Actual Values Expected Value

Coil Resistance [Red Wire / Brown Wire] D.V.M. Fluke 5 - 50
Coil Insulation [Red Wire / Multi Screen] 500v Megger 1M >200M
Coil Insulation [Brown Wire / Multi Screen] 500v Megger 1M >200M

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AquaMaster Parameter Detail Form

Parameter Name Item No. Value Comments

Software Version >0
Sensor ID No. >1
Sensor Serial No >17
Transmitter ID >207
Transmitter PIN >208
Profiling Factor Fp >30
Insertion Factor Fi >31
Pipe Size >32
Sensor Size (mm): >9
Gain >4
Reverse >7
Sig A resistance >234
Sig B resistance >235
Sig A Voltage (>V1.03) >328
Sig B Voltage (>V1.03) >329
Coil >243
Alarms >246
System Error Flags >290
Cal factor Battery >13
Flow >217
Velocity >219
User Span >25
User Zero >26
Mode >102
Cal factor Mains >10
Cal factor Battery >13
Flow Sensor Cal B >146
Flow Sensor Cal A >147
Flow Sensor zero correction >195
Flow Cutoff (Mains Mode) >317
Left Battery Usage (Days) >231
Right Battery Usage (Days) >232

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Meter under
investigation

Connect
Comms Wake-up
No Local No
? Tx
Comms

Replace one Battery Yes

or check Mains supply
AQUAMASTER DISPLAY ICONS
Yes
Check Alarm Status and
operational state of the Tx
Future Use

Replace L.H. Battery Replace R.H.

Steady State State Steady
Battery only Tx Battery

Flashing Flashing

If R.H. Icon On If L.H. Icon On

Replace that Battery Replace that Battery
First First

Mains Check condition of Icon

No
Icon Check condition Power Battery Lead OFF
No
OFF of Battery Lead OFF

Yes
Yes`

End Flashing State End

a.c.
Locate fault in
at Terminals No
supply
?
Connect Terminal to
Local Comms Stead
y
Yes

Read Alarms in Examine Sensor

Measurements Menu Cable Connections
[>246] Check
R.H. Power connector No Reconnect
fitted

Log-in @ am2k & set

listed alarm variables Connect Terminal to Yes
Local Comms. Go to
(If security 'Access Measurements Menu
Denied' contact ABB) Contact
Fault in AquaMaster
!""
No

Read
SIGA & B Ohms Check Sensor for Dirty Electrodes/Full of
>50k
Perform 'Soft' reset [>234 & Water
[>315=1] 235]

If water conductivity low adjust Trip Point

= 9999 [>140]

Icon
Is
OFF Read [>328 & 329] > +/-
Sensor No
(V1.1 & V2.0n only) 2V5
Empty
Yes
Yes Yes
End
Fill Meter Check Sensor
Section Earthing

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Sensor Alarm Present
Check Sensor Wiring

Power
Mains
Mode

Battery

Measure
Orange w.r.t. Green &
Yellow w.r.t Green

Battery Mains

Pulsing
No No >3V2
to >3V3

Yes Switch Yes

Off
AquaMaster

Tx o.k.
Tx o.k.
Suspect Sensor wires
Suspect Sensor wires
Is
Orange/Yellow
No
Short Cct to
Green
Open Cct wires to
Sensor or Faulty Tx
Yes

Locate Cable
Fault

Sensor health can be tested

using ABB's AquaMaster Sensor Contact
Verification Test box !""
(Type: V V G)

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Power-up Error
Codes

Tx Version Tx Version
Watch Display from
V1.02, V1.03 V1.1, V1.2
V1.04, V1.06 Cold start-up V2.0n V2.1n

Behavior of Icons has

changed with later
versions.
See 'Icon Operation '
Specification sheet
EEFAIL1
EEPASS EEFAIL3
EEFAIL2

PASS Err 1 Err 2 Err 3 Err 4

No
Fault No
Fault

Go to
Sensor
wiring Log-in
checks Connect Local Comms Lead & [>248=am2k]
go to 'Measurements' Menu -
Alarms (or read [>246])
Unprogrammed
Sensor eeprom Reset Tx
[>315=1] &
Read Variable Watch display
number(s)s after
':'
Contact
Yes !""

Log-in
[>248=am2k]
Does Err 4
No
Any Persist
more Alarms
?
Set variables
Yes
listed and then
No
reset Tx
[>315=1] Contact
End End
!""

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Pressure Measurement
not working correctly

Is
Check Isolating valve at measurement at
Yes
pressure tapping point atmospheric
pressure

Yes

No

Was
the valve open and Connect another
Yes
water pressure Pressure Gauge to Tx
present

No

Investigate pressure Is
tapping reading now No
correct

Check AquaMaster variables in

Menus:

Yes 6.0 Pressure Settings,

8.0 Pressure Setup &
Yes 8.1 Pressure Transducer Calibration

End

Any Variables
required
correction

No

Suspect AquaMaster
Transmitter

Contact
!""

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Pulse Output
Not working

Connect Local
Terminal

Go to 'Measurements
Menu & check Pulse
O/P Frequency [>258]

Is O/P Hz
running & in correct No
direction

Yes Check Tx mode

[>102]

Is
Frequency in
range 0.01 - 1Hz

Adjust pulse
Yes
factor until it is
- or set 'Test'
Connect DMM mode 'On'
set to 'Ohms' [>233]
to PA1(2) &
PACOM
Also check
settings of
Output
variables
[70 & 71]

Is Output
Faulty AquaMaster
No Switching
Pulse Output
(>100K/<10ohms)

Yes

Contact Investigate remote

!"" device

Page 7 of 14 Technical Support Flow Products

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Remote
Communications
not working
Battery Mains

Wake-up
comms by Is
pulsing 'RI' to Remote device No
'ON'
+5V

Switch
'ON'
Note: Battery Yes Device
powered equipment
will time-out after
40s if there is no
comms traffic Measure RXD,
TXD, RTS, CTS
w.r.t. Serial GND

Is Is
RXD >-5V No RXD =0V Yes Faulty remote device
? ?
Yes No

Is Is
Check AquaMaster Mains
TXD >-5V No TXD =0V Yes
supply or apply Pulse to 'RI'
? ?
Yes No

Is Is
Check AquaMaster Mains
RTS >+5V No RTS =0V Yes
supply or apply Pulse to 'RI'
? ?
Yes No

Is Is
CTS >+5V No CTS =0V Yes Faulty remote device
? ?

Yes No

Check Comms
If Comms
setting on
states not
Remote Device
correct data
(Baud rate
may not flow
4800 & flow
control 'ON')

Check wiring is
correct

Contact
!""

Page 8 of 14 Technical Support Flow Products

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Is the flow indication
correct ?

Sanity Check

Has the flow value

come from the
customer based on
a logger or the
AquaMaster ? Do the Electrode
Resistance
Measurements look
o.k. ?
Are there any
Alarms ?
Check Coil Current
[243]
58-80mA Battery
170-190mA Mains
Look for flow noise
on display

Check:
[4] = 3 (ish)
[9] = Sensor Bore
[10] = Sensible Cal Fact
[11] & [195] = <200
[12] & [29] = 180 - 400+
[25] = 1
[26] = 0
294 = 58 (ish)
296 = 58 (ish)
Read [219] & [220]
These are the If you are happy that
uncorrected & everything looks o.k. -
corrected velocities. Report -
Should be within a 'The Product is good'
factor of 5

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Meter Flow Direction
Control

Flow Meter Mode [102]

If the flow direction behavior
of the AquaMaster needs Q 'Normal' operation. V out = Vin (all velocities).
modifying, there is a Q>0 'Forward Flow Only'. V out = Vin (Vin >0); Vout = 0 (Vin<0)
comprehensive range of
-Q 'Reversed' operation. V out = -Vin (all velocities).
settings available.
-Q>0 'Reverse Flow Only'. V out = -Vin (Vin< 0); Vout = 0 (Vin>= 0).
~
NEVER reverse the Coil
wires.
Vout Vout Vout Vout

Vin Vin Vin Vin

Q Q>0 -Q -Q>0

Pulse Output
Direction Control

Pulse Output Units (67)

Pulses Per Unit (68)
Maximum Pulse Freq. (69)

o/p state o/p state

Output 1 Function (70) OP1 -v +v -v +v

0 OFF
1 ON OFF ON
2 Pulse FWD
3 Pulse F+R
o/p freq. (Hz) o/p freq. (Hz)

-v +v -v +v

Pulse FWD Pulse F+R

o/p state o/p state o/p freq. (Hz)

Output 2 Function (71) OP2
0 OFF
1 ON -v +v -v +v -v +v
2 Pulse R
3 Fwd FWD REV Pulse R
3 Rev
Output vs. Velocity(v)

Page 10 of 14 Technical Support Flow Products

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Battery life not up to
spec'

The 3V6 Lithium Cells are high

quality, long life components.
Possible Causes It is not common to get a problem,
however, it can happen on the odd
occasion

There is a very complicated Battery

management system that looks after
Check [158] = 15 the Cell switching.
This system is able to identify battery
changes and perform load tests.
Check [12] = < 440 It will also check Cells during and
Is it: prior to use.
very hot (> +40C)
or V1.2 & V2.10 Software has more
very cold (< -10C) advanced Cell management.

Communicating
frequently and
leaving the Menu
'Logged-in' will drain
the Cells
Are light/dark
changes taking
place frequently ?
Cell weaknesses e.g. Traffic over a
manhole cover. Are people messing
about with the
batteries and
corrupting the 'Days
used' counters?
Output resistance
goes high Has the Tx suffered
Above 6 ohms any lightning or
(approx) will cause static damage ?
premature failure
Capacity shortened
by extreems of
temperature
Physical damage to
wire or connectors

Page 11 of 14 Technical Support Flow Products

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Electrical Bonding AquaMaster

These instructions will enable you to correctly cross bond the meter.
Two aspects are required:

1. If the AquaMaster is installed in a metal pipeline then to ensure no potential differences

get developed across the meter, the meter must be bonded with the supplied electrical
strap on the flange to the upstream and downstream pipeline. Even if the inside of the
pipeline is lined or insulated coating such as concrete, this cross bonding is required.
This is best achieved by a welded stud on each end of the connecting pipe, or a tapped
hole in the flange. Use at least a 12 gauge (4mm 2 cross section) copper or stainless
steel braid wire for all connections. Special consideration is required if very high pipeline
currents are flowing such as with cathodically protected pipelines. The following
diagrams on should give good installation conditions for the majority of cases. See also
current product installation manual

2. The second aspect is to ensure the sensor has a good reference to pick up the signal on
the fluid. Due to the differing construction methods used in the manufacture of the
sensors, 80mm (3) sizes and below have exposed stainless steel ends in contact with
the fluid and no further steps are necessary. Sizes 100mm (4) sizes and above must
have two fluid contact rings and these must be fitted as per the General arrangement
indicated below. Even of the pipeline is metal these fluid contact rings are required.

Note:

1) The Flow Sensor must not be connected to an Earth spike.

2) For Electrical Bonding connections use 4mm2 (10 AWG)

3) Sensors 80mm do not require fluid contact rings.

N.B.

If the transmitter is remote from the sensor, then it is also required to connect the transmitter case

external terminal to the sensor meter body as shown in figure 6. Note this is not required for an

integral unit, where it is connected automatically by the meter construction.

It is important for correct operation not to connect the sensor or the transmitter to an extra earth spike
or similar as this will often be at a different potential to the pipeline and will cause unwanted currents
to flow, which may corrupt the meter measurement.

Page 12 of 14 Technical Support Flow Products

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There are a number of different scenarios, metal pipe, plastic pipe, lined metal pipe etc. the
following should cover most of them. In all scenarios a connection should be made between
the pipe and the external earth point of the transmitter as shown in Figure 6

Fluid Contact Ring

Fluid Contact Ring

Fig 1 Metal Pipes Lined & unlined Fig 2 Metal Pipe with VJ coupling to Plastic
Pipe

. .

Fluid Contact Ring Fluid Contact Ring

Fig 3 Flanged Metal Pipe to Plastic Fig 4 All Plastic Pipe

. .

Fluid Contact Ring

Cross bonding ring

Fluid Contact Ring
Fig 5 Metal Pipe with Plastic Make
up Insert

Fig 6 Battery Powered Transmitter mounted in

chamber

Page 13 of 14 Technical Support Flow Products

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In some installations, there appears to be significantly higher voltages than the norm, these
will often perform badly with conventional methods of potential equalistaion. For these
installations ABB has developed a potential equalising ring with an increased surface area,
and will be shipping these with all AquaMasters.

Fig 11

Pipelines with Cathodic Protection

Page 14 of 14 Technical Support Flow Products

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