Modernization Made Easy: How to Effortlessly Replace MAG 5000/6000 with SITRANS FMT020

 

In many industrial applications – whether in water management, chemical production, or food processing – electromagnetic flow measurement systems such as the MAG 5000 or MAG 6000 from Siemens have been in use for years. These devices have proven to be reliable, but with ongoing digitalization and increasing communication demands, they are reaching their limits.

However, a complete replacement of such systems can have significant consequences:

• Long downtimes that disrupt ongoing operations or lead to costly production losses,

• complex rewiring or mechanical adjustments,

• as well as high investments in new sensors.

For many operators, this raises a key question:
How can I modernize my system without replacing the existing sensors?

The answer is the SITRANS FMT020 – a modern transmitter specifically developed for easy retrofitting into existing Siemens MAG systems. Thanks to full backward compatibility, it allows the replacement of outdated transmitters without modifying the sensors – quickly, cost-effectively, and with minimal installation effort.

 

→ What does backward compatibility actually mean?

In industrial measurement technology, backward compatibility refers to the ability of a new device to work seamlessly with older, already installed components or systems. For operators, this means that new technologies can be integrated without having to modify existing sensors, cabling, or process connections.

In the case of the SITRANS FMT020, this specifically means:

• • • SITRANS MAG 5100W – standard solution for water and wastewater applications

    • SITRANS MAG 3100 / 3100P – for industrial media, even under aggressive conditions

    • SITRANS MAG 1100 / 1100F – for hygienic processes and compact installations

      The transmitter is compatible with a wide range of older Siemens MAG sensors such as:

• • No mechanical modifications, no reconfiguration of sensors, and no change to the installation position is required.

• • The existing sensors remain in the process – only the old transmitter (e.g. MAG 5000/6000) is replaced with the FMT020.

 

 

Why is this especially relevant for operators?

 

Thanks to this backward compatibility, the SITRANS FMT020 becomes an ideal retrofit solution, bringing digital performance into existing plant structures – quickly, safely, and economically.

 

→ Benefits of the SITRANS FMT020 for Modernization

Modernizing flow measurement points is often associated with extensive interventions in existing systems – especially when not only the transmitter but also sensors, cabling, or process connections are affected. This is exactly where the SITRANS FMT020 comes in: As a backward-compatible transmitter, it was specifically developed to replace existing Siemens MAG systems like MAG 5000 or MAG 6000 quickly and cost-effectively – without modifications to the existing infrastructure.

 

Plug-and-Play with older Siemens sensors

The FMT020 is fully compatible with existing sensors such as MAG 3100, MAG 5100W, or MAG 1100.
This means:

• Existing sensors remain installed in the process.
  → No removal, no recalibration, no downtime due to mechanical work.

• Easy transmitter replacement via plug-and-play.
  → The FMT020 automatically detects compatible sensors and adopts basic parameters.

• Wiring and flange connections remain unchanged.
  → Especially important in installations with limited space or access.

 

Easy commissioning

Thanks to intelligent assistant functions and a well-thought-out user interface, commissioning the FMT020 is especially efficient:

• Quick start assistant:
  Guides users through the key configuration steps – ideal for standardized applications or series replacements.

• Intuitive operating menu on the integrated display:
  Clear navigation via button controls, easily readable LCD – even in difficult lighting conditions.

• Remote access via HART or optional Bluetooth module:
  Parameterization conveniently via laptop, tablet, or maintenance station – without access to the measuring unit.

 

Cost reduction through targeted retrofitting

Modernizing with the FMT020 offers clear economic advantages compared to a complete replacement:

 

→ Practical example: Retrofit in the water industry

The water and wastewater sector depends heavily on continuously operating measurement points. A failure in flow measurement can not only compromise process reliability but also violate regulatory requirements. In one typical case, a faulty MAG 6000 transmitter was identified at a municipal waterworks – however, the sensor itself (a SITRANS MAG 5100W) was still fully functional.

Instead of replacing the entire system, the old transmitter was replaced with the SITRANS FMT020 – quickly, easily, and without any intervention in the pipeline.

Step-by-step: Retrofit instead of full replacement

1. Removal of the defective MAG 6000

• Disconnect the power supply

• Loosen terminals, remove the device

• Sensor remains untouched in the pipeline

2. Installation of the SITRANS FMT020

• Mount FMT020 on the existing bracket

• Connect to existing wiring (identical connector)

• Sensor is automatically detected

3. Commissioning

• Activate quick-start assistant

• Check basic parameters such as medium, pipe diameter, and output signals

• Measuring point fully operational again in under 30 minutes

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Comparison: Retrofit vs. Full Replacement

Thanks to the backward compatibility of the FMT020, the existing measuring point could be put back into operation in no time – without any piping work, without recalibrating the sensor, and without unnecessary downtime costs. Operational safety was fully restored – while simultaneously paving the way for modern communication and future diagnostic functions.

 

→ Future-proofing through modern communication

With the SITRANS FMT020, it is not only possible to modernize older Siemens MAG systems – the device also prepares existing installations for the demands of digital process automation. Thanks to its versatile interfaces and diagnostic functions, the transmitter is a future-ready component for any measuring point.

Modern communication interfaces – directly integrated

The FMT020 supports a wide range of communication protocols, allowing flexible integration into both existing and new automation systems:

• HART 7: Universal communication via existing 4…20 mA signals – ideal for retrofit applications.

• Modbus RTU / Modbus TCP: Open protocols for PLC and control systems – widely used in the industry.

• PROFIBUS and PROFINET: Perfect for use in Siemens-based environments with real-time communication.

• EtherNet/IP: For modern automation architectures in process and manufacturing industries.

• Optional: Bluetooth interface: For wireless access to diagnostics, parameterization, and maintenance – via app or notebook.

This enables users to seamlessly connect existing measuring points to digital controllers, SCADA systems, or cloud platforms – without modifying the sensors or infrastructure.

 

Diagnostics and condition monitoring with SITRANS Verificator

The FMT020 is fully compatible with the SITRANS Verificator – a test and diagnostic tool used to evaluate the functionality and accuracy of the entire flow measurement system.

Key benefits at a glance:

• Fast verification of the measuring chain (sensor + transmitter) without removal or process interruption

• Documented results for audits, ISO 9001, or internal quality assurance

• Wear detection or deviations are identified at an early stage

This turns a simple transmitter into a central component for predictive maintenance and cost-optimized servicing.

Ready for digitalization – without breaking the system

With the FMT020, it is possible to balance the use of existing assets with future-proof upgrades:

• Existing sensor technology is retained

• Modern communication is added

• Digital diagnostic data is centrally available

Whether as part of a retrofit strategy or as a building block for an Industry 4.0 architecture – the SITRANS FMT020 ensures that your measurement technology remains fully integrated and high-performing, today and in the future.

 

→ Summary: Investment protection meets digitalization

With the SITRANS FMT020, Siemens offers a well-designed solution for all operators looking to modernize their existing measurement technology economically while preparing for a digital future.
The transmitter combines technological advancement with maximum compatibility with existing MAG sensors,
making it especially attractive for plant operators with a mixed or aging equipment base.

Instead of expensive complete conversions, companies can simply continue using their existing sensors – while also taking advantage of modern features such as:

• digital communication (HART, PROFINET, Modbus, etc.),

• diagnostic capabilities via
  SITRANS Verificator,

• and convenient parameterization via Bluetooth

at the same time.

The FMT020 therefore offers true investment protection:
it extends the lifecycle of existing sensors, reduces downtime, and lowers maintenance and installation costs.
At the same time, it enables entry into a connected, future-ready measurement system without complex reinstallation or process interruption.

Conclusion:
If you want to bridge the gap between existing assets and digital development,
the SITRANS FMT020 offers a practical and compelling solution – with
minimal effort and maximum impact.