mrčela promag 33

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Flow MeasurementService Manual

SH 005D/06/e/07.96No. 50069552

General Information Service Manual Promag

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General informationThis manual is written for service technicians and the measuring system should only be repaired byqualified personnel.

This service manual describes the measuring systems Promag 30/33/35S and 39. It is valid for softwareversions V1.01.XX (amplifier) and V1.00.XX (communications module) and above. Further informationson updating and supplements are available from your local Endress + Hauser Sales Office.

The operating manuals for the measuring systems Promag 30 (BA008D/06/e/...), Promag 33(BA009D/06/e/...), Promag 35S (BA021D/06/e/...) and Promag 39 (BA024D/06/e/...).are also part of thisservice manual.

SafetyWarning

The instruments are built and checked according to EN 61010, “Protection Measures for ElectronicEquipment for measurement, Control, regulation and Laboratory Procedures“ and have left the factory ina safe and perfect condition.

When removing the housing cover under power, the protection status is no longer valid. Therefore,always switch off the power supply before opening the instrument.

Ex devices should only be opened after the mains voltage is switched off and after a minimum coolingtime of 10 minutes.

Do not carry out repairs or soldering in hazardous areas.

Under no circumstances should soldering of the boards be carried out by service engineers. Do notunsolder any SMD components. All existing regulations covering Ex boards must be strictly adhered to!

All local regulations concerning the operation and repair of electrical instruments must be strictly observed.

Regulations governing repairAll instruments sent to Endress + Hauser for repair must be free of all dangerous or poisonous chemicals(acids, lyes, solvents, etc.). Please do not return instruments unless every possible step has been taken tocompletely remove dangerous material, if you do send instruments back to the factory for repair pleasesend them with the completed form “Recognition of safety“ signed by the user.

The Promag measuring system fulfils all protection requirements of IP 67 and NEMA 4X (sensor option IP68, Promag 39 transmitter IP 20 only). All screws of the transmitter and sensor housing should be undoneby qualified and trained personnel only otherwise the guarantee covering the protection requirements isno longer in force. All gaskets and screws are to be replaced and tightened.

Release of programming levels for Promag 33/35S/39Release of programming level: 33, 35, 39 (factory set), according to deviceRelease of service programming level: 4685

Checklist of service items• Multimeter with continuity tester• Portable two-channel oscilloscope• Flowjack with Promag adapter• Replacement electronics module• Prospy software, Prospy interface, Laptop or PC

Service Manual Promag Summary of Contents

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Summary of contents Page

General information ..........................................................................................................2Safety..............................................................................................................................................2Regulations governing repair.......................................................................................................... 2Release of programming levels for Promag 33, 35S and 39.........................................................2Checklist of service items................................................................................................................2

Appliance overview ........................................................................................... 4

1. Instructions on troubleshooting ..............................................................................51.1 Response of the measuring system to fault or alarm.........................................................51.2 System check for Promag 30.............................................................................................61.3 System check for Promag 33, 35S, 39..............................................................................71.4 Possible errors, causes and remedial action...................................................................... 81.5 Checking the amplifier using test points

TP2/TPField and TPIref/TPField................................................................................................. 131.6 Checking the communications module of the Promag 33, 35S, 39.................................. 141.7 Simulation of current and frequency output on the Promag 33, 35S, 39..........................161.8 Connecting the Flowjack (Promag 30, 33, 35S)................................................................161.9 Checking the sensor........................................................................................................... 161.10 Using the service software Prospy......................................................................................17

2. Electrical data ...............................................................................................................182.1 Connection diagrams for the remote version Promag 30/33 (FS)..................................... 182.2 Connection diagrams for the remote version Promag 35S................................................182.3 Connection diagrams for the remote version Promag 39..................................................192.4 Cable specifications for the remote version (FS)................................................................192.5 Cable length/conductivity.................................................................................................... 202.6 Fuse ratings ........................................................................................................................202.7 Coil resistances...................................................................................................................202.8 Sampling rates (SAPS table)..............................................................................................21

3. Repair and service.................................................................................................................223.1. Replacing the electronic board, diagrams of boards..........................................................223.2 Block diagram.....................................................................................................................293.3 Updating the electronics from Promag 30 to Promag 33..................................................303.4 Updating power supply variants..........................................................................................303.5 Updating options.................................................................................................................303.6 Electromagnetic compatibility EMC/RFI.............................................................................313.7 Operating overview of Promag 30......................................................................................313.8 Local display Promag 30.................................................................................................... 323.9 Operating overview of Promag 33, 35S, 39 (incl. matrix)...................................................333.10 Service labels......................................................................................................................353.11 Exploded drawing and spare part lists for Promag 30, 33, 35S, 39.................................. 363.12 Exploded drawing and spare part lists for Promag 39.......................................................38

Service Manual Promag

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Appliance overview

Promag A

Promag D

Promag H

Promag FDN 25...300(Remote version)

Promag Fwith DIN 11851DN 25...100(Remote version)

Promag FDN 350...2000(Remote version)

Promag 30(with display)

Promag 33/35S

Promag 33/35S(Remote version)

Promag 39

Service Manual Promag 1. Troubleshooting

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1. Instructions on troubleshooting1.1 Response of the measuring system to faults or alarms

Condition ofmeasuring. system

Transmitter

Response of measuring system

System operatingcorrectly

Promag 30

Promag33/35S/39

• Status output closed,i.e. open collector = conducting

• Relay contact* Relay 1 = closed

Fault, system error

Error due toinstrument failure orpower failure

Promag 30

Promag33/35S/39

• Status output open,i.e. open collector = non-conducting

• Pulse output not operating

• Current output set to 0 or 2 mA according to programmedresponse on error

• Error message shown on display

• Relay contact* Relay 1 = open

• Signal outputs respond according to programmedresponse on error

Process faultAlarm

Error due to processconditions

Promag 30

Promag33/35S/39

• Status output open, i.e.open collector = non-conducting)

• Pulse output not operating

• Current output set to 0 or 2 mA according to theprogrammed response on error

• Error message shown on the display

• Response of Relay 2 according to configuration

• Error output (Relay 1) not affected

• EPD installed: signal outputs respond according toprogrammed response on error

* Factory set Relay 1 = make contact set. The break contact can also be set as required by using a jumper on the communications board (see Page 27).

Note !

Positive zero return and simulation: The response of the measuring system is changed if these functionsare activated. They should be deactivated during diagnosis (troubleshooting).

Please refer to the section on positive zero return and simulation in the operating manual.

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1. Troubleshooting Service Manual Promag

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1.2 System check for Promag 30

Is the power supply voltage presentacross Terminals 1 and 2?

Is the fuse in the wiring compartmentOK?

Is the status output set to error indication?

Does the status output have high resistance?(open collector = non-conducting)(“open collector” = non conducting)

Does the status output have lowresistance if a 3...30 VDC voltage ispresent at the auxiliary output?

No system or processerror is present: check theoutputs and parameters.

There is a system error present!With local display: ERRORindication!Check the electronics (see Page13 onwards) and replace ifrequired.With the service tool Prospy theerror and history of previous errorscan be read out.

There is a process error present!• Check measuring range• Check process conditions of plant

(e.g. measuring pipes not completelyfilled).

yes

yes

yes

yes

no

no

Check wiring!

Replace the fuse! (Ratings on Page20)

no

no

yes

Switch No. 2: Set to “OFF”

no


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1.3 System check Promag 33/35S/39

Does the display light up?

Is there a status message on the display?S:......

Is there an error message on the display?

No system or process error ispresent. Check the wiring of theoutput signal cable or other possiblesources of error. (See Page 8onwards.)

Is there asystem error orinstrumenterror?F:.....

Use diagnosis function to call up theerror description. Carry out correctiveprocedures (see following pages).

Is there aprocess errorpresent?Alarm?A:......

Program the instrument according toprocess conditions or change theprocess parameters (e.g. flow velocity <10 m/s). See also the descriptions ofprocess errors in the operating manualSection 6.

yes

yes

yes

no

yes

no

no

Is the power supply voltage presentacross Terminals 1 and 2?

Is the fuse in the wiring compartementOK?

yes Check wiring!

Replace the fuse! (Ratings on Page20)

no

no

yes

Switch off the power supply andswitch it on again while pressing the“+/-” keys simultaneously. Thesystem starts with maximumcontrast in English language.

yes If the positive zero return, currentoutput or frequency simulation areactivated, then switch off thesefunctions!Other status messages are to benoted.

no


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1.4 Possible errors, causes and remedial actionPromag 33/35S/39: Error description by calling diagnosis function or check error output (relay 1).Promag 30: ERROR indication (with local display or Prospy) or check status output.Switch off positive zero return or simulation function if they are activated for error messages!

Error message F:..and system errors

Cause Remedial action

F: SYSTEM ERROR POWER SUPPLY

LOW VOLTAGE DETECTED

The power unit is supplying avoltage which is too low:

• Power supply defective.

• The power voltage to theinstrument is too low.

Replace power unit.

Check mains voltage toinstrument and increase it ifnecessary.

COIL CURRENT CONTROL

Coil current is outside tolerancelevels:

• Power unit defective.

• The mains voltage to theinstrument is too low.

• Open or short circuit of thesensor coil.

• Sample rate (SAPS) too high.

• Amplifier control defective.

Replace power unit.

Check mains voltage toinstrument and increase it ifnecessary.

Check coil, see Page 20 for coilresistances, check wiring.

See SAPS table on Page 21 andcompare with the setting of thesample rate in the function group“Sensor data”.

Replace electronics.

F: SYSTEM ERROR AMPLIFIER

EEPROM FAILURE

Error on access to EEPROM data(calibration values of measuringamplifier):

Amplifier defective. Replace amplifier board.


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F: SYSTEM ERROR AMPLIFIER

Promag 33/35S/39:

DAT FAILURE

Error on access to DAT data(calibration values of sensor).

Promag 30:

DAT failure:Current output set to 0/2 mA orERROR indication with localdisplay.

Re-enter sensor data and store.

Replace DAT and re-enter sensordataEmergency mode: DeactivateDAT.

Caution!The data is lost when the powersupply is switched off.

Note!The DAT data are also stored inthe Com-Module from softwareversion 2.01 upwards.

Replace DAT.

Note!DAT for Promag 30 can beprogrammed in a Promag 33instrument or by means of theProspy software.

ROM / RAM FAILURE

Error on access to programmemory (ROM) or workingmemory (RAM) of the processor:

• Amplifier defective.Replace amplifier board.

GAIN ERROR AMPLIFIER

Gain error of the measuringamplifier:

• Temperature compensationdefective,

• Amplifier defective.

Replace amplifier board.

Replace amplifier board.

NO AMPLIFIER RESPONSE

(Promag 33/35S/39 only)

Incorrect data transmissionbetween communication moduleand amplifier.

1. Communication module defective: replace.

2. If still defective replace amplifier board.

3. Measure at V6 usingoscilloscope (see Page 14onwards).


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F: VALUE NOT ACCEPTED


The value entered has not beenaccepted by the amplifier.

Repeat entry

Check whether other changes toparameters have been accepted.If these are not accepted either,then replace electronics.

F: SYSTEM ERRORCOM-MODULE


MODULE NOTCOMPATIBLE

Communication module andmeasuring amplifier are notcompatible.

• Incorrect Com-Module (Type).

• Software is incompatible; thefirst figure of the softwareversion of the Com-Moduleand the amplifier must beidentical (e.g. V2.xx.xx).

EEPROM FAILURE

Error on access to EEPROM data(process and calibration data ofCom-Module).

Replace Com-Module.

RAM FAILURE

Error on access to the workingmemory (RAM).

Replace Com-Module.

ROM FAILURE

Error on access to the programmemory (ROM). • Replace EPROM

(IC 4 on Com-Module)Replace Com-Module if stillnot OK

LOW VOLTAGE DETECTED

DC/DC converter on the Com-Module provides insufficient powervoltage.

Replace Com-Module.

VOLTAGEREFERENCE

Voltage reference unit of the Com-Module is outside tolerance, i.e.correct functioning of the currentoutput is not guaranteed.

Replace Com-Module.


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System errors Cause Remedial action

No reading on thedisplay

• Contrast too low.

• Defective display unit.

• Defective communicationmodule.

Switch off power supply and pressthe “+/-” keys. Switch on powersupply again. The system startswith maximum contrast in Englishlanguage.

Replace display unit.

Replace communication module.

Keyboard does notrespond

• Dirt on keypad.

• Defective display.

Clean keypad.

Replace display.

Programming level isnot accessed withpersonal code number(factory setting 33, 35S,39)

“CODE” has been changed orforgotten

Open programming level withservice code number 4685 andread off the “CODE” in the“system parameters”.

Critical measuring errors • Data are not correctlyprogrammed.

• Measuring tubes notcompletely filled.

• High gas content in medium.

• Incorrect connection of coil onremote version (mixing up e.g.Terminal 41 with 42), leads toneg. signal.

• Insulating coat on theelectrodes.

• Short circuit betweenelectrode cable and screen.

• H-circuit defective.

• Low coil insulation.

Check process and sensor data.Reprogram if necessary.

Ensure that the measuring tube iscompletely filled. A flowmeter withEPD may need to be used.

Increase system pressure or installgas separator upstream of theflowmeter.

Check coil connector at theterminal. A new connection maybe required (see Page 18/19).

Clean electrodes inside themeasuring tube. Clean periodicallyor increase flow velocity ifpossible.

Measure resistance betweenelectrode core and screen (>500V) with dry sensor. Electronicsmust be disconnected!

Check Iref with oscilloscope (see1.5).

Measure resistance betweenterminals 14 and 41/42 (>500V) (atsensor). Electronics must bedisconnected!

Note!If the coil insulation is low caused by condensation humidity, cleaning with concentrated alcohol may help!


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System errors Cause Remedial action

Strongly fluctuatingoutput signal with stableflow

• Conductivity of the medium istoo low

• Measuring tubes are notalways completely filled

• High gas content in medium

Measure the conductivity of themedium. Another measuringprinciple may have to be used.

Ensure that the measuring tube iscompletely filled. A flowmeter withEPD may need to be used

Increase system pressure or installgas separator upstream of theflowmeter.

• Open circuit in electrode cable

• High solids content in medium.

Check the electrode cablebetween the electrode andconnection board with a continuitytester or multimeter. The sensormust be replaced if there is anopen or short circuit.

Note!Flow signal is zero when shortcircuit.Check connection print/ electrodeplug before exchanging sensor.

Increase time constant in order toachieve a more stable currentoutput signal.

Increasing SAPS rate can help forsmall nominal diameters.

Unstable output signal

Measuring error

Application with plastic tubing andhigh equalising currents (e.g.stack gas desulphurisationsystems)

Switch off power supply andmeasure with an ammeter thecurrent between the electrodeconnection and the groundpotential of the Promag(measuring tube must be full).Grounding disks must be used if acurrent is detected.

The options RS 485 orHART cannot be used


Functions not activated Activate the functions using thekeypad (see operating manual orprogramming matrix Page 34).

EPD option cannot beused

• No EPD electrodes installed oroption not released.

• EPD has been incorrectlyinstalled.

Promag 33/35S/39: refer to thefunction group „PROCESSPARAMETER“ to see if EPD isinstalled and released.

Check wiring and correct ifnecessary (see Page 18/19).


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1.5 Checking the measuring amplifier at test points TP2/TP Field and TPIref/TPField

The test points for Promag 30/33/35S are located on the connection plug of the Flowjack (see Fig. 7,Page 16). At the moment the Promag 39 can be checked at the rear pins (see Fig. 11, Page 19).

Open the electronics compartment and connect the Flowjack flow simulator (for connection see Page16). Simulate sensor signals with the Flowjack. Using a two-channel oscilloscope, you can now check thesignals of the test points TP2/TPFIELD and TPIREF/TPFIELD against ground.

Results TP2/TPField: The signals at TP2 must be a mirror image for every field switching. If this is not thecase then the measuring amplifier must be replaced.

Results TPIref/TPField: The graph of TPIref must show a peak with every field switching. If this is not the case,then the H-circuit on the measuring amplifier is defective. The amplifier board and the power supply boardhave to be replaced.

If graphs such as these are given then the power supply unit and the measuring amplifier are functioningcorrectly (Promag 30). With the Promag 33/35S/39 the communication module has also to be checked(see Page 14 onwards.).

If the transmitter electronics are operating correctly then check the sensor (see Page 16).

Fig. 1:Signals at the testpoints TP2/TPField

Fig. 2:Signals at the testpoints TPIref/TPFELD

TPField

TPField

TP2

TPIref


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1.6 Checking the communication module of the Promag 33/35S/39

The operation of the communication module and the amplifier board can be checked with a two-channeloscilloscope. For Promag 33/35S the terminals of the oscilloscope are connected to the pin block V6 ofthe measuring amplifier (see Page 25/26). The assignment of the pin strip is shown in Fig. 3. For Promag39 TXD/RXD can be accessed only by the pin strips (see Fig. 11, Page 19)

Channel 1 of the oscilloscope is connected to TXD / PIN 1 and channel 2 to RXD/PIN 3.

Normal operating mode

Figure 4 shows the signals of the amplifier and the communication module when operating normally.Channel 1 (TXD) shows the transmission of the measured value from the amplifier to the communicationmodule. Channel 2 (RXD) shows acknowledgement of the communication module of the incoming value.This sequence is cyclical and repeats itself, e.g. with a sampling rate of 16.7 every 60 ms.

TXD

RXD

Fig. 4:Signals of amplifier andcommunication modulewith normal operation

Fig. 3:Assignment ofpin strip V6 for Promag33/35S

Pin strip V6

Pin strip V5

Ground


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Defective communication moduleIf the error message F: SYSTEM Failure AMPLIFIER occurs with the diagnosis NO DATA RECEIVED,then there may be a fault in the communication module. In this case, no signal is available from channel 2(Fig. 5) RXD/PIN 3 of the measuring amplifier as shown. The amplifier attempts to recreate a connectionwith the communication module which results in a periodic signal of approx. 200 Hz at TXD/Pin 1 (seechannel 1).

Defective amplifier boardIf the error message F: SYSTEM FAILURE AMPLIFIER occurs with the diagnosis NO DATA RECEIVEDthen the amplifier may be faulty. In this case there is no signal on the transmitting channel TXD/Pin 1 (seechannel 1 Fig. 6). The communications board attempts to recreate a connection with the amplifier. Thisresults in a periodic signal of approx. 200 Hz at RXD/Pin 3 (see channel 2).

TXD

RXD

TXD

RXD

Fig. 5:Signals with faultycommunication module

Fig. 6:Signals with faultyamplifier


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1.7 Simulation of current and frequency output on the Promag 33/35S/39Checking any electronics connected can be carried out by simulating the signals of the current output andalso the signal of the frequency output. The functioning of the simulation mode cannot be attributed to thefunctionality of the Promag electronics.

The current output is activated in the function group ANALOG OUTPUT and the frequency output isactivated in the function group PULSE OUTPUT. The desired values are also programmed in thesefunction groups.

1.8 Connecting the Flowjack flow simulator (Promag 30/33/35S)Sensor signals are simulated using the Flowjack. The Flowjack is connected via the two plug contacts onthe measuring amplifier board of the Promag 30/33/35S (see Fig. 7). The electrode cable must first beremoved from the pin strip V5.

1.9 Checking the sensorOn the sensor the following possible failures have to be ruled out:

• Short circuit measuring electrode/measuring electrode (measure with empty pipe)

• Short circuit measuring electrode/ground

• Short circuit of sensor coil (coil resistance see Page 20)

• Open sensor coil (coil resistance see Page 20).

Fig. 7:Connection of theFlowjack, test points andpin strips


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1.10 Using the service software Prospy

Using the service software Prospy is recommended when dealing with the blind Promag versions.

The prospy data transfer cable should be connected at pin strip V8 (see Fig. 7 on Page 16). Via theProspy interface box the Promag can communicate with the PC.

The following functions are available:

• Download: Downloading the complete program configuration of the Promag into the PC.

• Storing the configuration on the PC.

• Modifying the programming on the PC.

• Upload: Restore changed or modified data from PC to the Promag.

Fig. 8:Using the servicesoftware Prospy

2. Electrical Data Service Manual Promag

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2. Electrical Data2.1 Connection diagram for remote version Promag 30/33 (FS)

Promag 30/33 D, H, F Promag 30/33 A

Transmitter Transmitter

Sensor Sensor

2.2 Connection diagram for remote version Promag 35S

Fig. 9:Electrical connection forremote version Promag30/33 (FS)

Note:The connection area is integrated in the housing of the Promag AEPD - Empty Pipe Detection

Fig. 10:Electrical connection forremote version Promag35S

Service Manual Promag 2. Electrical Data

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2.3 Connection diagram for remote version Promag 39

2.4 Cable specifications for remote version (FS)The same cable is used for both the Promag 30 and Promag 33 .

Cable specifications

Coil cable 2 x 0.5 mm2 - PVC cable with common screenCable resistance: Promag 30/33/39: ≤ 37 Ω/km

Promag 35S: ≤ 12.5 Ω/kmCapacitance (core/core, grounded screen): ≤ 120 pF/m

Signal cable 3 x 0.38 mm2 - PVC cable with common screen andindividually screened coresWith optional Empty Pipe Detection (EPD): 4 x 0.38 mm2 - PVC cable

Cable resistance: ≤ 50 Ω/kmCapacitance (core/screen): ≤ 420 pF/m

Fig. 11:Electrical connection ofremote version Promag39

2. Electrical Data Service Manual Promag

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2.5 Cable length/conductivityThe permissible cable length Lmax between sensor and transmitter of >10 m is determined by theconductivity of the medium to be measured (see Fig. 12).If the EPD function is installed, then the maximum distance is 10 meters.The total cable resistance may not exceed 2.5 Ω, even with cable length >50 m.

2.6 Fuse ratingsThe fuses for the Promag 30/33/35S are accessible in the terminal compartment (Ex versions on thepower supply board). The fuse for the Promag 39 is on the power supply board (see Page 24f).

Power unit: 85...260 VAC Power unit: 20...55 VACPower unit: 16...62 VDC

Promag 30/33/35S/39 1 A (slow blow) 2,5 A (slow blow)

Promag 30/33/39 Exversion 1 A (slow blow,

sand filled)2.5 A (slow blow,

sand filled)

2.7 Coil resistancesIf there is an open or short circuit of the sensor coil, then this can be verified by measuring the coilresistance.

Coil resistance [Ω] at 20 °C

Promag 30/33/39 D(Discomag)

Promag 30/33/39 A(Picomag II)

for all nominal diameters 350 ± 5%

DN 25...100 DN 125...300 DN 350...600 DN 600...1200 DN 1200...2000

Promag 30/33/39 F(Pulsmag F)

115 ± 5% 145 ± 5% 140 ± 5% 160 ± 5% ---

Promag 35S for all nominal diameters 10 ± 5%

DN 25...65 DN 80/100

Promag H 114 ± 5% 140 ± 5%

Conductivity[µS/cm]

[m]

Permissiblerange

Cable length Lmax

Fig. 12:Cable length of remoteversion governed by theconductivity of the medium

Service Manual Promag 2. Electrical Data

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2.8 Sampling rates (SAPS table)If the sampling rates are set too high then the coil current cannot attain its optimum value. This is shownby e.g. measuring error. With the Promag 33/35S/39 the electronics generate the error message F:SYSTEM ERROR POWER SUPPLY: COIL CURRENT. With the Promag 33/35S/39 the sampling ratecan also be called up in the function group SENSOR DATA. This can be compared with the maximumpermissible values in the following table.

Max. sampling rate (SAPS)for Promag 30/33/39and sensors A/D/F

Max. sampling rate (SAPS)for Promag 35S

Max. sampling rate (SAPS)for Promag H

power supply

DNAC

50 HzAC

60 HzDC AC

50 HzAC

60 HzDC AC

50 HzAC

60 HzDC

2 12.5 12 13.8 - - - - - -

4 16.7 15 18.3 - - - - - -

8 16.7 15 18.3 - - - - - -

10 16.7 15 18.3 - - - - - -

15 16.7 15 18.3 16.7 15 18.3 - - -

25 16.7 15 18.3 16.7 15 18.3 25 25 25

32 16.7 15 18.3 16.7 15 18.3 25 25 25

40 16.7 15 18.3 16.7 15 18.3 25 25 25

50 16.7 15 18.3 16.7 15 18.3 25 25 25

65 16.7 15 13.8 16.7 15 18.3 25 25 25

80 16.7 15 13.8 16.7 15 18.3 25 25 25

100 16.7 15 13.8 16.7 15 18.3 25 25 25

125 10 10 9.2 - - - - - -

150 10 10 9.2 12.5 12 13.8 - - -

200 10 10 9.2 16.7 15 18.3 - - -

250 8.3 7.5 7.9 - - - - - -

300 8.3 7.5 7.9 - - - - - -

350 8.3 7.5 7.9 - - - - - -

400 7.14 6.67 6.87 - - - - - -

450 7.14 6.67 6.87 - - - - - -

500 6.25 6.00 6.11 - - - - - -

600 6.25 6.00 6.11 - - - - - -

700 5.00 5.00 5.00 - - - - - -

750 4.55 4.62 4.58 - - - - - -

800 4.17 4.29 4.20 - - - - - -

900 4.17 4.29 4.20 - - - - - -

1000 3.57 3.53 3.43 - - - - - -

1050 3.33 3.33 3.23 - - - - - -

1200 3.13 3.16 3.05 - - - - - -

3. Repair and Service Service Manual Promag

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3. Repair and Service3.1 Replacing the electronic boardsWarning!• Danger from electric shock! Switch off the power supply before unscrewing the cover to the electronic

compartment of the transmitter housing. Befor opening Ex devices wait ten minutes after switching offthe power supply.

• When replacing boards, ensure that the markings are identical (Part-No.). Exchange Ex modules onlyagainst Ex modules.

• Local power voltages and frequencies must agree with the technical specifications for the powersupply board used.

Procedure for Promag 30/33/35S:1 Switch off the power supply!

2 Loosen the locking clamp (3 mm Allen screw) andunscrew the cover to the electronics compartment.

3 Remove the local display unit by removing the ribboncable.

4 Remove the two-pole plug of the connecting cable bysimultaneously pressing the locking unit of the powersupply board.

5 Also remove the cable board of the screened electrodesignal cable from the amplifier board.

6 Option EPD Empty Pipe Detection:Loosen the two-pole pin terminal on the amplifierboard.

7 Loosen the two Phillips screws of the board support.Carefully remove the support approx. 4 - 5 cm out ofthe transmitter housing.

8 Remove the plug connection to the coil current cablefrom the power supply board.

9 Also remove the plug of the ribbon cable(= connecting the terminal compartment) from theamplifier board (for Promag 30 from the amplifier boardand for Promag 33/35S from the communicationboard.

10 If necessary, remove the DAT module from theparticular pin strip of the amplifier board.

• Required when replacing the amplifier board(transferring old DAT to new board)

• Required when replacing defective DAT (pluggingnew DAT on old amplifier board).

11 The complete transformer electronics unit can now beremoved from the housing together with the boardsupport.

12 Remove the appropriate electronics board and replace.13 Installation is done in reverse sequence.

Fig. 13:Replacing theelectronic boards (e. g.Promag 30, LC displayoptional)

Service Manual Promag 3. Repair and Service

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Warning!• Danger from electric shock! Switch off the power supply before unscrewing the cover to the electronic

compartment of the transmitter housing.• Switch off the power supply before pulling the cassette out of the rack. Otherwise you may destroy the

coil circuit.• When replacing boards, ensure that the markings are identical (Part No.)• Local power voltages and frequencies must agree with the technical specifications for the power

supply board used.

Procedure for Promag 39:1 Switch off the power supply!

2 Loosen the screws of the frame at the back of thedevice.

3 Pull out one after the other, power supply board (3)with fuse on, Com module (4) and amplifier board (5).

6 If necessary, remove the DAT module from theparticular pin strip of the amplifier board.

• Required when replacing the amplifier board(transferring old DAT to new board)

• Required when replacing defective DAT (pluggingnew DAT on old amplifier board).

7 If necessary exchange display board behind the frontplate..

Fig. 14:Replacing theelectronic boardsPromag 39


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Power supply board Promag 30 and Promag 33

Power supply board Promag 35S

Fig. 15

Pin strip for coil cable Mounting screw

Socketboard

Socketboard

Mounting screw

Fig. 16

Mounting screw

Mounting screw

Socketboard

Socketboard

Plug forpower cable

Pin strip for coil cable

Plug forpower cable


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Power supply board Promag 39

Amplifier board Promag 30

Pin strip for connecting the flow simulator „Flowjack“

Test point 2Mounting screws

Socket

Socket

Sockets for ribbon cable plug(connection to the terminalarea)

Mounting screw

Pin strip for DATmodule

Miniature switchesNo. 1...10

Pin strip for electrodesignal cable

Connecting terminals EmptyPipe Detection:Terminal 1 : cable

screening (red)

Terminal 2 : signal cable (yellow)

test point 2 test point 1 fuse

test point 3

Fig. 17

Fig. 18


26

Amplifier board Promag 33/35S

Amplifier board Promag 39

Fig. 19

Pin strip for connecting the flow simulator „Flowjack“

Test point 2 Mounting pin

SocketsMounting pin

Pin strip for DATmodule

Pin strip for electrodesignal cable

Connecting terminals EmptyPipe Detection:Terminal 1 : cable

screening (red)

Terminal 2 : signal cable (yellow)

Pin strip for DAT module

Fig. 20

Test point 2


27

Communications module HART Promag 33/35S

Communications module RS 485 Promag 33/35S

Relay 1: Error output

Relay 2: Status output,can be configured

Fig. 21

Relay contact: Make and break settings

Make contact setting Break contact setting

JumperJ5, J6

JumperJ5, J6

Factory setting Relay 1 Factory setting Relay 2

Mounting screws

Sockets for ribbon cableplug (connection to theterminal area)

Socket for ribbon cable plug(connection to the displaymodule)

Jumper (Relay 2): make/break contactJumper (Relay 1): make/break contact

Sockets for ribbon cableplug (connection to theterminal area)

Socket for ribbon cable plug(connection to the displaymodule)

Jumper (Relay 2): make/break contactJumper (Relay 1): make/break contact

Mounting screws

Miniature switch for configuration

Fig. 22


28

Communications module Promag 39

Fig. 23


29

3.2 Electronics block diagram

Fig. 24:Block diagramof measuring systemPromag


30

3.3 Updating electronics from Promag 30 to Promag 33The following components are required for updating:

Components Order No.

• Electronic modules (power supply board, amlifierboard, Com-Module)

• Display module Promag 33 (if blind version notrequired)

• Electronics compartment cover Promag 33(if blind version not required)

• Service label (see Page 35)

(see spare parts list on Page 36)

Dismantle the entire Promag 30 electronics and replace them with the appropriate components of thePromag 33. Ensure that the power supply board has the same voltage. Fill out the service label and fixinto the housing.

Caution!The original DAT module of the updated instrument must be used!

3.4 Updating power supply variantsThe following components are required for updating the power supply:

Components Order No.

• Electronic module (with the correct power supplyboard)

• Filter board

• Caution!Ensure that the power supply board and the filterboard have the same voltage.

• Service label (see Page 35)

(see spare parts list on Page 36)

Dismantle the entire Promag 30 electronics and replace them with the appropriate new components.Ensure that the power supply board has the correct voltage. Fill out the service label and fix into thehousing.

Caution!The original DAT module of the updated instrument must be used!

3.5 Updating options

Option ProcedurePromag 30:Local display

Change the electronics compartment cover and install thelocal display. Connect to the amplifier board (see Page 25f);

version 2.01.xx or above possible.

Promag 33/35S/39:

HART®

RS 485/E+H-RackbusRS 485/auxiliary input

Exchange the complete electronics module against onehaving the required hardware and software (see Page 25f).


31

3.6 Electromagnetic Compatibility EMC/RFIThe Promag measuring system is protected against electromagnetic interference and fulfils the standardsEN 50081-1, EN 50082-2 and NAMUR recommendations. However, should problems arise in the directvicinity of frequency converters, phase controllers or other sources of strong electromagnetic radiation(radio waves, microwaves, X-rays, etc.), then the following procedures should be carried out:

• In order to take full advantage of theelectromagnetic compatibility of the Promagmeasuring system, it is recommended that twoflange-to-flange connections are made andconnected together to the ground potential onthe transmitter housing (see Fig. 25). A 6 mm2

copper cable should be used.

Caution!This is not permitted for piping with cathodicprotection.

• Where the remote version is used, ensurethat the connection cable does not lie in thesame cable tray with other cables which are

connected to or which supply power to the Instrument.

3.7 Operating overview of Promag 30The instrument parameters of the Promag 30 can be set using the miniature switches. These are foundon the amplifier board (see Fig. 18). The cover to the electronic compartment must be removed to set theswitches.

Warning!Switch off the power supply before opening the cover to the electronic compartment.

Miniature switch No. 1...10 (factory set)

ON

OFF

1 2 3 4 5 6 7 8 9 10

Setting of full scalevalue

Setting of pulseweighting

Creep suppression Configuration ofstatus output for:

Flow directionindication

Indication ofprocess errorssystem errors,power failure

Fig. 25:Ground in areas withstrong electricalinterference Groundingin electrically starkinterference fields

System units

US units[gal]

SI units[dm3, m3]

1 gal = 3,7854 dm3 (liter)

Current range

0...20 mA

4...20 mA

ON

OFF

1

1

ON

OFF

2

2

ON

OFF

3

3

ON

OFF

4

4

ON

OFFFig. 26:Setting the miniatureswitches for the variousfunctions of the Promag30

switch


32

3.8 Local display Promag 30With the Promag 30 local display the following parameters can be read off directly at the measuring point:

• Flow quantity and/or totaliser value• Technical units (SI/US)• Process conditions (creep suppression, empty pipe, etc.)• Error messages

Selecting and activating various functions may be done using the three operating keys. These areaccessible by unscrewing the cover of the electronics compartment. The keys are moved using a thin rod.Switching takes approx. 0.5...0.8 seconds.

JumperLeft side: The auxiliary inputis configured for “measured value

Right side: The auxiliary inputis configured for “totaliserreset”

SetThe following operations are carried out within thefunction using this key:

• Selecting technical units

• Switching Empty Pipe Detection on/off

• Starting full/empty pipe setting

LCDAll measured values, operating and status messagesare shown here.

11 Display segmentsThe appropriate segments serve to identify thetechnical units, instrument and process conditions:

• Actual technical units

• Creep understepped (low flow cutoff)

• Velocity of medium >12.5 m/s (overflow)

• System fault (Error)

• Partial pipe filling (Empty Pipe; Empty PipeDetection)

Totaliser resetThe totaliser is reset to “0” using this key (possiblewith function “tot” only)

Display functionThe required function (= display mode) is selectedusing this key. Continuous pressing of the key runsthrough the various functions:

• Actual flowrate

• Actual totaliser value

• Number of overflows of the totaliser display

• Alternating displayflow <=> totaliser

• Empty Pipe Detection

• Empty pipe setting

• Full pipe setting

• Test function to check the display elementsFig. 27:Local display Promag30 and functionelements


33

3.9 Operating overview of Promag 33/35S/39Operation of the Promag 33/35S transmitter is carried out using three optical keypads.The Promag 39 is operated by three push buttons.

Selecting the individual function groups within the E+H programming matrix is done by operating theoperating keys in sequence. The diagnosis function is activated by simultaneously pressing the +/- keys.

Fig. 28:Display and operatingelementsPromag 33/35S/39

HOME position(display during normal operation)

Procedure:

1 Enter the <GROUP SELECTION>

2 Select the function group

3 Select function

4 Return to HOME position after programming

< GROUP SELECTION > FunctionsFunction groups (selecting parameters, entering values) Fig. 29:

Selection of functions by theE+H programming matrix


34

Programming matrix Promag 33/35S/39Reprogramming the transmitter is generally locked. Parameters can only be entered or changed after acode number has been entered (factory set = 33, 35 or 39).

Fig. 30:Programming matrixPromag 33/35S/39


35

3.10 Service labelsAfter upgrading Promag units service labels should be filled out and attached into the transmitter housing.

Fig. 31:Service labels


36

3.11 Exploded diagram and replacement parts list Promag 30/33/35S

Fig. 32:Exploded diagramPromag 30/33/35S


37

Replacement parts list Promag 30/33/35SElectronics module Order No.

A1

Electronic modules PromagData storage DAT Promag

see sparepart list50068175

Display module

BB

Display module Promag 30Display module Promag 33/35S

5006347550059324

Filter board

CCCCCC

Filter board Promag 20...55V AC, 16...62 V DCFilter board Promag 85...260V ACFilter board Promag 20...55 V AC, 16...62 V DC, EXFilter board Promag 85...260V AC, ExFilter board Promag 35S, 20...55 V AC, 16...62 V DCFilter board Promag 35S, 85...260V AC

500732965007329550069615500696145007467950074678

Connection board

D Connection board Promag 50058490Housing

EEE23345678888910111213

Housing Promag 20...55V AC, 16...62V DCHousing Promag 85...260V ACHousing Promag E+H blueSeal for connecting boardFuse 250 V AC T 2A50Fuse 250 V AC T 1A00Fuse coverCable conduit plate PromagStrain release unit Promag-PMFLocking clampCable gland PG 13.5Cable gland PG 13.5/M20 x 1.5Cable gland PG 13.5/NPT 1/2“Cable gland PG 13.5/G 1/2“Cover Promag display moduleCover Promag for blind versionCover Promag terminal compartmentO-Ring 113.90 x 3.53Sealing plugs for PG 11/13.5

! 10 units! 10 units! 50 units

! 50 units

50059315500593145005725550058507500492635001775750060722500584885005633150058913500207095004919550049194500644605005936150056514500565175005909650049055

Separate version Promag 30/33 transmitter

Connection housing Promag separate version 50060667Small components14151617181920212223

Flat-head screws KA25 x 10Fillister head screw M3 x 8Fillister head screw M3 x 8Fillister head screw M4 x 12Fillister head screw M4 x 10Allen screw M4 x 16Spring washer M4Spring washer M4Ground wire terminalGround terminal

! 50 units! 50 units! 50 units! 50 units! 50 units! 50 units! 100 units! 100 units

50020017500433835005867950041698500586785001738850058677500173615002273850017499

Service labelsService label Promag 30Service label Promag 33 (blind version)Service label Promag 33 (display version)Service label Promag 35S

500620965006209550062094on request

! Minimum quantity


38

3.12 Exploded diagram and replacement parts list Promag 39

Replacement parts list Promag 39Electronic insert module Order No.A,B,C1123

Electronic boards Promag 39Fuse T 2A00 / 250 V ACFuse T 1A00 / 250 V ACFuse coverData storage DAT Promag 39

see spare! 10 units! 10 units! 50 units

part list50019159500177575006072250061301

Housing4567891011121314

Housing Promag 39Front plate Promag 39GripFlat-head screws KA25 x 10Fillister head screw M2.5 x 11Plastic inletBack plate 21 TEFillister head screw M3 x 6Spring washer M3Flat-head screw M2.5 x 5Spring washer M2.5

! 10 units! 50 units! 50 units! 50 units

! 50 units! 100 units! 50 units! 100 units

5007543150075000500200245002001750020016500200055002021450019345500174385002002250020020

Fig. 33:Exploded diagramPromag 39

mrčela promag 33

Documents

spare parts

high gas content

head screws

test points

spare part

empty pipe

local power

increase system