Mag 5000 / 6000 & Associated Sensors

Installation & Fault Finding Guide

Mag 5000 / 6000 & Associated Sensors
nstallation & Fault Finding Guide

Stephen Howes Product Manager

Siemens AG
5/31/2017

Call us on +44 (0)1449 674 986 visit www.pisales.co.uk

Page 2 of 30
Index …
A.0 Recommended Tools Page 5

1.0 Mechanical Installation Page 6

1.1 Sensor Installation Page 6

1.2 Sensor Prom Installation. Page 7

2.0 Wire Connections Page 8

2.1 Wire Connections for Compact Sensor. Page 8

2.2 Wire Connections for Remote Sensor. Page 8

2.3 Cable Specifications Page 9

2.4 Examples of Good and Bad Installations. Page 10

2.5 Overview of Transmitter Connections Page 11

3.0 Parameters Page 12

3.1 Basic Settings Page 14

3.2 Output Parameters Page 15

3.3 Service Menu Page 16

3.4 Sensor Characteristics Page 18

4.0 Fault Finding. Page 19

4.1 Error Codes. Page 19

4.2 Sensor Fault Finding. (Sensor Full) Page 21

4.3 Sensor Fault Finding. (Sensor Empty) Page 22

4.4 Coil Resistance Table (Connections 85 & 86) Page 23

5.0 Sitrans FM Magflo Verificator – Important Instructions Page 24

5.1 Verificator – Check List Page 26

6.0 Appendix. Page 27

6.1 Flow Meter Check List, Compact. Page 27

6.2 Flow Meter Check List, Remote. Page 27

6.3 Sensor Operating Range Page 28

6.3 Cable Kit Part Numbers Page 29

7.0 Technical Support Page 30

Page 3 of 30
Page 4 of 30
A.0 Recommended Tools

Insulation Tester 500V.

Example
RS Pro, Insulation Tester 4000M CAT III 1000 V
RS Stock No. 893-7913

Moving Coil Meter

Example
Maplin MT 2017 Large Analogue Multimeter
Code: N60LK

Page 5 of 30
1.0 Mechanical Installation
1.1 Sensor Installation
Sensor needs to be full at all times. Vertical Pipes

Avoid positioning measuring electrodes at top and bottom of pipe.

Straight Diameters for optimum performance

Page 6 of 30
1.2 Sensor Prom Installation.

1 2 3 4

1
Sensor shipped with Sensor-Prom installed in junction Box.

2
Remove SensorProm before potting terminal box’

3
Make sure Sensor-Prom details match details of Magflow Sensor, Cal Factor & Serial Number

4
Install Sensor-Prom into transmitter REMOTE junction box (as shown).

Page 7 of 30
2.0 Wire Connections
2.1 Wire Connections for Compact Sensor.

2.2 Wire Connections for Remote Sensor.

Page 8 of 30
2.3 Cable Specifications

Double screened electrode cable

(81/82/0/83/84)

Use for long cable runs and/or

empty pipe detection See Appendix
for cable kit part numbers.

Keep un-screened lengths to less

than 50 mm

Colour Code for Factory Cable Kit.

Reveres 85 & 86 connections at one

end to correct flow direction.

Keep un-screened lengths to less

than 50 mm

Page 9 of 30
2.4 Examples of Good and Bad Installations.

Verificator insulation test failed Verificator insulation test Passed

Wrong cable and un-screened

lengths greater than 50mm

Unstable readings and failed

Verification Insulation Test

Wrong cable and un-screened

lengths greater than 50mm

Unstable readings and failed

Verification Insulation Test

Page 10 of 30
 2.5 Overview of Transmitter Connections

Electrode connections – 82, 0, 83 standard configuration with No empty pipe detection (EPD).
Terminals 81 and 84 used for empty pipe detection, and can only be used with Siemens supplied double
screen cable. Screen cable at sensor end only. Keep unscreened lengths to a maximum of 50mm.

Coil connections - 85 – 86 standard screened cable can be used. Connect screen to earth and sensor
and transmitter. Keep unscreened lengths to a maximum of 50mm to prevent corruption of electrode
signal.

Page 11 of 30
3.0 Parameters

The factory setting of 1000 can be re-established as

follows:
Switch off power supply
Press the TOP UP (Top Left) key and switch
on the power supply
Release the key after ROM and RAM tests
are completed
The user code is now reset to 1000.

Page 12 of 30
Page 13 of 30
3.1 Basic Settings

Page 14 of 30
3.2 Output Parameters
Current Output

NOTE:
Current Output - “Time Constant” effects response time of unit, (Mag 6000/5000) not just the
mA output.
Time Constant can only be altered if mA is set to ON.
If the output terminals (31, 32) are not connected , Turn off mA output after adjusting “Time
Constant”, this will prevent P42 alarm. May require power re-cycle to clear alarm.

Digital Output Set to Pulsed

Page 15 of 30
3.3 Service Menu

Excitation frequency can be used to check for noise,

1. Lower Low flow cu-off to 0.1%
2. Turn Off Excitation.
3. Any flow value indicated on the top line would indicate
excessive noise.
4. Do not use the Verificator, and check electrode and coil
cables.

Signal suitability is a level from 0 to 9 of the electrode measured

voltage.
Level 0 is equal to the limit value that is set for empty pipe error
detection, and level 9 is the best signal measured.

Page 16 of 30
3.3 Service Menu Continued

The error system

The error system is divided into an error pending list and a status log list. Time
is gained as days, hours and minutes since the error has occurred.
The first 9 standing errors are stored in error pending. When an error is removed it is
removed from error pending.
The latest 9 errors are stored in the status log. When an error is removed it is still
kept in status log.
Errors in status log is stored for 180 days.
Error pending and status log are accessible when enabled in the operator menu.

Page 17 of 30
3.4 Sensor Characteristics

Sensorprom must be installed. If not

all data can be programmed manually (*)

If Sensorprom NOT installed

Error code 40 can be suppressed
Parameter is not visible when Senor Prom installed

Sensor size – if no sensorprom is installed then

sensor size must be programmed in metre. Eg, DN
100 = 0.100
Parameter ”Read Only” when Senor Prom

Calibration Factor from wet calibration – can be

found on sensor label and calibration report.
Parameter ”Read Only” when Senor Prom
installed

Correction Factor - must be 1.0000

To be changed in special conditions only

Excitation frequency according to Sensor size.

See Handbook for correct selection.
Parameter ”Read Only” when Senor Prom
installed

Page 18 of 30
4.0 Fault Finding.

4.1 Error Codes.

The converter system is equipped with an error and status log system with 3 groups of information.
1. Information without a functional error involved
2. Warnings which may cause malfunction in the application. The cause of the error may
disappear on its own.
3. Permanent errors which may cause malfunction in the application. The error requires an
operator intervention.
4. Fatal error which is essential for the operation of the flowmeter

2 menus are available in service and operator menus for registration of information and errors
1. Error pending
2. Status log

Two Flashing Triangles indicate a Fault Condition

The current Error can be viewed in run Mode

Press Until Error Pending is Displayed

Error Logs Can be view under Service Mode

Page 19 of 30
4.1 Error Codes Continued..

W = Warning P = Permanent F = Fatal

Page 20 of 30
 4.2 Sensor Fault Finding. (Sensor Full)

1 Check coil resistance with Remove remote cables and Faulty Coil Cable Replace
a multimeter: recheck coil resistance with and recheck
R85-86 Nominal value: multimeter:
see table R85-86 Nominal value:
see table

Faulty Sensor check

WARRENTY

2
Remove cables and re-
Check coil insulation with Faulty Coil Cable Replace
Check coil insulation with
a megger (500 V) and recheck
a megger (500 V)
R85 or 86 – GND
R85 or 86 – GND
Nominal value: Infinite
Nominal value: Infinite
resistance
resistance

Faulty Sensor check

WARRENTY

Check electrode circuit Remove cable and re- Faulty Electrodes Cable
with a moving-coil check electrode circuit Replace and recheck
instrument without
amplifier. Note: If Both Values are
R82-0 > 500 kohm,
Nominal value: Dirty Electrodes
5 – 500 kohm Empty Pipe
R83-0
Nominal value:
5 – 500 kohm
Faulty Sensor check
WARRENTY

Sensor Healthy,
Proceed with Verification

Page 21 of 30
 4.3 Sensor Fault Finding. (Sensor Empty)

Check coil resistance with Remove remote cables and Faulty Coil Cable Replace
a multimeter: recheck coil resistance with and recheck
R85-86 Nominal value: multimeter:
see table R85-86 Nominal value:
see table

Faulty Sensor check

WARRENTY

Remove cables and re-

Check coil insulation with Faulty Coil Cable Replace
Check coil insulation with
a megger (500 V) and recheck
a megger (500 V)
R85 or 86 – GND
R85 or 86 – GND
Nominal value: Infinite
Nominal value: Infinite
resistance
resistance

Faulty Sensor check

WARRENTY

Remove cables and re-

Check electrode Faulty Coil Cable Replace
Check electrode
insulation with a megger and recheck
insulation with a megger
(500 V)
(500 V)
R82 or 83 – GND
R82 or 83 – GND
Nominal value: Infinite
Nominal value: Infinite
resistance
resistance

Faulty Sensor check

WARRENTY

Check continuity between electrode and

terminal.
R82-electrode Nominal value: 0 K ohm
R83-electrode Nominal value: 0 K ohm

Page 22 of 30
4.4 Coil Resistance Table (Connections 85 & 86)

1 ) On MAG 1100 DN 15 produced as from May 1999 the coil resistance must be 86 ohm, +8/ 4 ohm.
All resistance values are at 20 °C.
The resistance changes proportionally 0.4% / °C.

Page 23 of 30
5.0 Sitrans FM Magflo Verificator Important Instructions

BEFORE VERIFICATION
Steps 1 to 5 below MUST be completed before verification is carried out

1. Make sure the Sitrans FM sensor is full of liquid and the flow meter is
operating.
2. Switch off the power to the flow meter to be verified.
3. Remove the transmitter (Mag5000 or Mag6000).
4. Ensure sensor and transmitter are correctly earthed.
5. Insulation Check – Coils.
Using an insulation tester (megger), with 500v insulation voltage, check for
correct insulation between the electromagnetic coils and ground.
Measure the resistance between terminal 85 and ground, then between
terminal 86 and ground.
The resistance should be infinite (greater than 500 Megohms).

If the insulation test fails, DO NOT connect the Verificator to the flow meter.
Warning: Connecting to a flow meter which has failed insulation will
damage the Verificator.
Typical repair cost: £2000.00 to £3000.00.

CONNECTING THE VERIFICATOR

Steps 6 to 9 MUST be done with power disconnected from both Verificator
and flow meter.

6. Place the Verificator close to the transmitter.

7. Plug the 3 colour coded flying leads into the adaptor.
(Line up the plug and socket red dots and push firmly into place).
8. Place the adaptor onto the terminal box and secure the screws.
9. Plug the transmitter into the Verificator.

DURING VERIFICATION

10. Switch on the power to the Sitrans FM flow meter.

11. Turn on the Verificator power switch.
12. Wait for Verificator to display the “File #” list.
13. Choose the file name for the flow meter to be verified.
14. Press the “Go” key to start the test.

Refer to the Verificator manual for detailed information about the verification
process and diagnostic messages.

Turn over for further instructions…

Page 24 of 30
Important:
Do not press the keypad or change any settings on the transmitter during
the verification process.
Never switch off power to the Verificator during a test, unless the test has
been stopped (by pressing the “Esc” key).

AFTER VERIFICATION

15. When the verification is finished press “Go” to return to the main menu and
automatically store the data.
16. Turn off the Verificator power switch.
17. Switch off the power to the Sitrans FM flow meter.
18. Remove the adaptor and re-fit the transmitter.
19. Switch on the power to the Sitrans FM flow meter.

Warning
Disconnection of the transmitter or the Verificator adaptor during a test
may damage the Sensorprom module, the transmitter or the Verificator.

In normal use the Verificator power cable (maximum 2.5m) should be used
in a workshop environment when downloading data to a PC following site
verifications.

Page 25 of 30
5.1 Verificator – Check List

Coil circuit (connections 85 & 86) must be Megger tested with reference to earth
before using Verificator. Failure to comply too this procedure can result in damage to
Verifcator. If in doubt please contact Siemens.
There are a number of possible reasons why the Verificator may fail the Insulation test on a Magflo flowmeter.
The most common reasons are listed below.

1.0 Converter Failed

1. Press ESC to end Verification
2. Replace MAG5000/MAG6000

2.0 Insulation Test Failed

2.1 Compact Mounted Converter
1 Black moulded coil and electrode connectors not mounted on the connection card.
2 The pipe is not full of fluid.
3 Moisture in the connection box.
4 Electrodes or coil circuit grounded. (Carry out sensor checks)

2.2 Remote mounted converter

1 The pipe is not full of fluid.

2 Meter body not grounded to the fluid. (Confirm if Magflo type has earthing electrodes or an earthing
ring fitted).
3 Incorrect wiring connections of the coil and electrodes
4 Unscreened lengths of wire on the electrode circuit. Max unscreened 50mm (better with 25mm
max) at any point including Junction Boxes and cabling inside panels.
5 Discontinuous screen in any Junction Boxes or panel terminations.
6 Incorrect cable being used i.e multi core (spare cores act as signal pick up aerials) or unscreened
cables.
7 Two separate cables not used for coil and electrodes.
8 Screen on the coil cable not connected at both ends
9 Crimps used on wiring and poor connection made.
10 Moisture in either the sensor or remote electronic connection boxes.
11 Electrodes or coil circuit grounded. (Carry out sensor checks)
12 Lightning arresters in circuit. (These have a built in grounding circuit)
13 Crossed connection between two sensors i.e electrode connections made to a different converter to
the one driving the coils.

If possible try a signal converter compact mounted in order to eliminate cable problems. From our experience
incorrect cable installation is the main cause of Insulation failure when using the Verificator.

3.0 Sensor Failed – Magnetism Fault

Data relating to magnetic properties deviates from data stored in Sensor-prom
Trouble shooting may reveal: -
1. Short circuit within excitation coils or to ground, This may have damaged Verificator.
2. Bad or missing connection of coil cable.
3. Corrosion or loose connection within the magnetic circuit.
4. Foreign magnetic material within the flow sensor
5. Sensor-prom failed or corrupted (Indicated by error F61 on signal converter display)
6. Changing excitation frequency from default can cause a coil error change back to default while
performing Verification.

Page 26 of 30
6.0 Appendix.

6.1 Flow Meter Check List, Compact.

Action Passed
Check power connection for the Mag 6000, including earth connection
Check Earth connection to bottom plate
Ensure Sensor Prom is installed and serial number matches serial number on
junction box
Ensure Molded plug (2 pins) with indication 85 & 86 is connected to PCB with
corresponding number.
Ensure Molded plug (3 pins) with indication 82, 83 & 0 is connected to PCB with
corresponding number.
Insert Communication card into base of Mag 6000 transmitter if required.
Test coil insulation at 500 Volts, measure 85, to earth, and 86 to earth.
With Moving coil meter test electrode circuit (see page xx)
Fit Mag 6000 transmitter and tighten 2 fixing screws.
Turn on power and check for and errors.

6.2 Flow Meter Check List, Remote.

Action Passed
Check power connection the Mag 6000, including earth connection
Remove Sensor Prom from sensor junction box
Ensure Sensor Prom is installed in remote transmitter and serial number matches
serial number on junction box of connected sensor
Fit white terminal block to metal plate in sensor using x2 fixing screws.
Fix Molded Plug into white terminal block in sensor ensuring all screw as tight
Using recommended cable make wire connections in accordance with page xx.
Ensure unscreened lengths in sensor and transmitter are less than 50mm.
Insert Communication card into base of Mag 6000 transmitter if required.
Test coil insulation at 500 Volts, measure 85, to earth, and 86 to earth.
With Moving coil meter test electrode circuit (see page xx)
Fit Mag 6000 transmitter and tighten 2 fixing screws.
Turn on power and check for and errors.

Page 27 of 30
6.3 Sensor Operating Range

Ideal flow velocities between 0.5 and 5 m/sec meter will operate up to 10m/sec.

Page 28 of 30
6.4 Cable Kit Part Numbers

Cabling:
Cable kit with standard coil cable, 3 x 1.5 mm2/18 gage with shield PVC and electrode cable
double shielded, 3 x 0.25mm2 (-30 to +70 deg C)

Steel Wired Armoured Cabling:

Cable kit with standard coil cable, 3 x 1.5 mm2/18 gage with shield PVC and electrode cable
double shielded, 3 x 0.25mm2 (-30 to +70 deg C).
Important: Due to the weight of the cable, armoured cabling is not suitable for pre-potted sensors.

Page 29 of 30
Call us on +44 (0)1449 674 986
Or visit www.pisales.co.uk