How it Works
Badger Meter
Loading...
4000
Specifications
2 pgs255.36 Kb0
Operating Manual
24 pgs1.12 Mb0
Table of contents
Loading...

Badger Meter 4000 Operating Manual

Flow Sensor
Series 4000
SEN-UM-01714-EN-01 (April 2018)
User Manual
Flow Sensor, Series 4000
CONTENTS
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Mechanical Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation for PVC Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation of PVDF Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Electrical Wiring for a Digital Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Electrical Wiring for an Analog Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Impeller Assembly and Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Electronic Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Detecting Coil Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Calibration Pipe Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Wetted Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Digital Meter Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Analog Meter Specications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Technical Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pressure, Temperature Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Check Using a Digital Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Checking the Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Checking the Electronic Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Checking the Impeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Check Using an Analog Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Connecting Via DIC COM Port. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Page 2 April 2018SEN-UM-01714-EN-01
Flow Sensor Conguration Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Analog Loop Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Flow Rate Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Part Number Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Electronics Repair Kit Part Number Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Page 3 April 2018 SEN-UM-01714-EN-01

Introduction

INTRODUCTION
The Series 4000 Flow Sensor has an in line, flow-through design using a tangential six bladed impeller. The Sensor is available in 1/2 in. (12.70 mm), 3/4 in. (19.05 mm) and 1 in. (25.40 mm) pipe sizes, and a wide range of pressure and temperature specifications.
The sensors have a molded housing, rotating impeller and externally mounted electronics housing using a proprietary, nonmagnetic sensing technology. The closed, six-bladed impeller design provides higher and more constant torque than four-bladed designs, and is less prone to fouling by water borne debris. The shape of the impeller and the absence of magnetic drag provides improved operation and repeatability even at low flow rates. The housing design allows the impeller, bearings, shaft or O-rings to be cleaned or replaced without removing the sensor from the piping system.
Two signal output options are available. One option is a square wave frequency proportional to flow rate. Power for the circuit is provided by an external source through a three-wire shielded cable. An internal preamplifier allows the signal to travel a maximum of 2000 ft (609 m) without amplification, and 20 ft (6 m) of three-conductor cable is included. The second output option is a 4…20 mA current analog signal. Power is provided by the two-wire loop so the distance from the receiver is a function of power supply voltage and wire resistance. A maximum 30 in. (762 mm) connector cable is included.
Sensors of similar type are interchangeable, so there is no need for recalibration after servicing or replacement.
Theory of Operation
The Sensor operates by converting kinetic energy (in the flow stream) into rotation (of an impeller). Almost all flow sensors work on the principle of converting flow energy to output signals. The only arguable exceptions are ultrasonic and electromagnetic sensors. The interaction of the flow stream and the impeller depend, to a currently unquantified extent, on fluid properties (density, viscosity, and pressure) and on physical properties of the impeller. The Badger Meter impeller design features the following:
• A low mass polar moment of inertia
• No magnetic drag
• Very low eddy current drag
• Low bearing friction The impeller housing forms the periphery of a rotating fluid stream, the only source of drag tending to retard the impeller.
The efficiency of this design is the key to the repeatability of sensor output at very low flow rates, and is the reason that the pressure drop across the installed sensor is so low.

MECHANICAL INSTALLATION

Vibration

There is a direct relationship between sensor housing vibration levels and impeller wear. Sensors mounted in a low vibration region (close to pipe supports) consistently give longer bearing life than those mounted in a high vibration region. The difference in bearing life persists, independent of impeller and shaft materials, or methods of construction. The wear is most obvious at high flow rates, when high levels of pipe vibration are most pronounced.
When mounting a Sensor, minimize housing vibration using either of the following methods:
• Mount the sensor as close as possible to a stable, low vibration, anchored inlet or outlet pipe. Provide 10 diameters upstream and 5 diameters downstream of straight pipe.
• Provide pipe supports, on both sides of the sensor, that are firmly anchored to a stable platform. This is particularly important if the sensor is mounted in the approximate center of a pipe section two feet long between supports.
You must minimize sensor vibration, or sensor accuracy will be affected and impeller life reduced.
Page 4 April 2018SEN-UM-01714-EN-01
Mechanical Installation
Accuracy
The accuracy of flow measurement depends on proper location of the sensor in the piping system. Irregular flow velocity profiles caused by valves, fittings and pipe bends can produce inaccurate overall flow rate indications even though local velocity measurement might be accurate. A sensor located in the pipe where it can be affected by air bubbles, floating debris, or sediment might not achieve full accuracy, and could be damaged. Follow these directions for maximum system accuracy:
• Install the sensor in a pipe with 10 pipe diameters of straight pipe upstream and 5 pipe diameters of straight pipe downstream of the sensor for no flow disturbance. Allow no pipe bends, valves, other fittings, pipe enlargements and reductions in this length of pipe.
• For horizontal flow applications, install the sensor with the curved portion of the housing down. Sensors installed with the curved portion in the up position trap air, causing inaccurate flow measurement, especially at low flows. Sensors installed with the curved portion pointing sideways not only trap air, but increase impeller friction, which might also affect measurements at low flow rates. Install the sensor to facilitate servicing.
• The preferred vertical location is with liquids flowing up. If vertical flow downward is the only option, the pipe must be completely filled with fluid. Any circumferential orientation is correct, but the sensor location should facilitate servicing. A vertical location might result in reduction of accuracy.
• Mount sensors with a minimum of 3 in. (75 mm) clearance in all directions around the gray electronics assembly to prevent electro-mechanical interference. This space requirement applies to multiple sensor sensors installed in close proximity as well as to other EMI generators, such as electric motors or controls for motors, heaters or lighting.

Installation for PVC Sensors

Any compatible size and type of fitting or adapter can be connected to the pipe nipples by thermal or solvent welding. Make sure the fittings and method you choose to install the PVC unit comply with American Society for Testing and Materials (ASTM) standards. Install the sensor so the arrow in the stainless steel cover is pointing the same direction as the flow of the fluid. Do not connect directly to reducing or enlarging fittings. Install an additional 10 diameter upstream and five diameter downstream allowance if this is unavoidable.

Installation of PVDF Sensors

PVDF sensors are supplied with combination end connections. A Heat Weld Female Slip connection can accept most metric sized PVDF pipes. The external thread is used with George Fisher type Unions. Badger Meter® offers PVDF, 316SS FNPT, and CPVC Slip Socket Union Ends.
In PVDF sensors with the enhanced flow feature, the flow enhancement jet must be inserted before installing the sensor into the system. With the stainless steel cover facing you, insert the jet into the left socket (upstream end) and then perform the method chosen for installation. Install the sensor with the arrow on the stainless steel cover pointing in the same direction as the flow of the liquid. Follow the same ten and five diameter upstream and downstream allowance and orientation recommendations, as described in "Installation for PVC Sensors".
Page 5 April 2018 SEN-UM-01714-EN-01

Electrical Installation

ELECTRICAL INSTALLATION
Sensor part Cable supplied
Digital Transmitter 20 ft (6 m) of 20 AWG three-conductor cable with drain wire and shield
Analog Unit 30 in. (762 mm) of AWG two-conductor cable with drain wire and shield
Make electrical wiring connections according to accepted trade practices.
You can attach an electrical junction box directly to the sensor electronic module, or mount it in the vicinity of the sensor. Locate it conveniently to facilitate replacement of the electronic module assembly. Do not subject the wiring connections to water or conductive liquids, as these might impair operations or damage the sensor circuitry.
When connecting to the electronic device, observe the wire colors and polarity to allow proper performance and to prevent damage to the sensor or electronic device.

Electrical Wiring for a Digital Unit

Below are the general wiring instructions for the digital output unit. If you are connecting to a Badger Meter flow monitor, consult the user manual.
1. Connect the red sensor wire to the positive (+) wire or terminal.
2. Connect the black sensor wire to the negative (–) wire or terminal.
3. Connect the white sensor wire to the signal (S) wire or terminal.
4. Connect the bare sensor wire to sensor shield.

Electrical Wiring for an Analog Unit

Turn off the 4…20 mA power and finish all wiring before turning on the loop power.
1. Wire the red wire (+ analog loop) of the ow sensor to the positive (+) output of a DC power supply.
2. Wire the black wire (– analog loop) of the ow sensor to the positive (+) input of your analog device.
3. Wire the negative (–) input of your analog device to the negative (–) of the DC power supply.
Power Supply
10...35V DC
(– output) DC
(+ output) DC
(+ analog loop) Red
(- analog loop) Black
4xxx10-xxxx Flow Sensor
Figure 1: Wiring for analog 4000
Analog Input
Device
(–) Input
(+) Input
OTE:N Some legacy units may have additional orange and brown wires. Do not connect these wires. Connecting to these
wires will damage the unit and void the warranty. They are for factory calibration only.
Calibration
If you are replacing an existing sensor and have already calibrated your flow monitor, no calibration changes are necessary. For installation of a new flow monitor, please refer to the calibration instructions in the flow monitor manual.
Page 6 April 2018SEN-UM-01714-EN-01

Maintenance

MAINTENANCE

Impeller Assembly and Shaft Replacement

The following tools are required for the replacement of the impeller and shaft:
• 5/32 in. Allen wrench
• Flat blade screwdriver
• Torque driver in in-lb with 5/32 in. male hex adapter
OTE:N Units are factory calibrated at 12 in-lb.
1. Depressurize the pipe on which the sensor is being serviced.
DO NOT REMOVE SOCKET HEAD CAP SCREWS WHILE SYSTEM IS UNDER PRESSURE.
2. Using the Allen wrench, loosen and remove the four #10 socket head cap screws along with the stainless steel cover. It is not necessary to remove the electronics to service the impeller and shaft.
3. Use the at-blade screwdriver to pry the impeller cover/shaft assembly from the sensor housing by using the provided slots alternately.
4. Inspect the impeller and impeller cover/shaft assembly for signs of wear.
5. Replace the O-rings before reassembly. Do not use lubricants on the O-rings.
6. Insert the impeller into the cavity of the sensor housing, making sure the six blades are pointing into the ow direction. The unit does not operate if the impeller is positioned incorrectly. For example, if ow direction is to the right, position the impeller with blades pointing to the left. See Figure 2.
7. Orient the keyway of the impeller cover/shaft assembly to the small slot between the two large slots and align the shaft to the shaft hold of the impeller.
8. Hand press the impeller cover/shaft assembly into the sensor housing cavity.
9. Fasten the stainless steel cover to the sensor housing using the #10 socket head cap screws.
10. Torque the #10 hardware to 12 in-lb.
11. Pressurize the system.
ALL FOUR SCREWS MUST BE IN PLACE AND TORQUED CORRECTLY BEFORE PRESSURIZING SYSTEM!
Flow
Direction
PVC Version
Impeller
Impeller Cover/Shaft Assembly
Stainless Steel
Cover
#10 Hardware
Figure 2: Assembly and shaft replacement
Page 7 April 2018 SEN-UM-01714-EN-01
Maintenance

Electronic Assembly Replacement

A #1 Phillips screwdriver is required for servicing electronics. It is not necessary to depressurize or drain the system to service the electronics.
1. Disconnect the sensor wiring from the display or transmitter.
2. Using a Phillips screwdriver, remove the two #4 Phillips head screws and accompanying hardware.
LETTING THE ELECTRONIC ASSEMBLY DROP FROM THE SENSOR COULD DAMAGE THE DETECTING COIL.
3. Unplug the coil from the electronics
OTE:N On analog units, the coil is permanently attached to electronics.
4. Plug the coil into the replacement electronics.
5. Reattach the electronics to the sensor with the two #4 Phillips screws. See "Replacement Part Numbers" on page 20 for replacement part numbers.
MPORTANTI
Make sure the wires from the coil are tucked in before tightening the screws.

Detecting Coil Replacement

A #1 Phillips screwdriver is required for replacing the detecting coil. Depressurizing or draining the system is not necessary for detecting coil replacement.
1. Remove the electronic assembly like in step 1 in "Electronic Assembly Replacement".
2. Unplug the coil from the electronics.
3. Using a Phillips screwdriver, remove the two #6 Phillips head screws, and the coil retaining plate.
4. Secure new coil to sensor housing with the #6 hardware.
5. Plug the replacement coil into the electronic assembly.
6. Fasten the electronics to the sensor with the #4 hardware. The coil wire orientation is not critical to operation. See
"Replacement Part Numbers" on page 20 for replacement part numbers.
Coil
Coil Retaining Plate
#6 Hardware
Electronic Assembly
#4 Hardware
Figure 3: Coil and electronic assembly replacement
Page 8 April 2018SEN-UM-01714-EN-01
Impeller Body
Loading...
+ 16 hidden pages
Buy Points How it Works FAQ Contact Us Questions and Suggestions Privacy Policy Cookie Policy Terms of Use