Badger Meter 4000 Sensor - 1/2, 3/4"", 1"" User Manual

Series 4000

®

Flow Sensor

872121-EN (April 2012)

Rev. 2

IMPORTANT:

This manual contains important information.

READ AND KEEP FOR REFERENCE.

Installation & Operation Manual

Series 4000

Page ii April 2012

Installation & Operation Manual

CONTENTS

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

MECHANICAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Installation for PVC Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Installation of PVDF Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

ELECTRICAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Electrical Wiring-Digital Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Impeller Assembly and Shaft Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Detecting Coil and Electronic Assembly Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

REPLACEMENT PART NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

CALIBRATION TABLE-DIGITAL OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

TROUBLESHOOTING THE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Digital Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Analog Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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Series 4000

Page iv April 2012

Installation & Operation Manual

INTRODUCTION

Data Industrial® nonmagnetic flow sensors by Badger Meter provide an accurate measurement of liquid flow. The Series 4000
flow sensor covers applications for ½ " to 1" pipe sizes and a wide range of pressure/temperature specifications. When used
in conjunction with Badger Meter Series 1500, Series 2000, and Series 300 electronics, the measurement may be displayed or
transmitted as a rate or total.

The Series 4000 sensors consist of 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 five volt DC square wave frequency proportional to flow rate. Power
for the circuit is provided by a Badger Meter flow monitor or other external source via a three-wire shielded cable. An internal
preamplifier allows the signal to travel 2,000 feet without amplification, 20 feet of three conductor cable is provided with this
option. The second output option is a 4-20mA 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 30 inch connector cable is provided with the
analog version.

Sensors of similar type are interchangeable, so there is no need for recalibration after servicing or replacement.

Figure 1: Models

MODELS

Badger Meter provides several basic sensor configurations using the same impeller element. This allows for a wide range
of applications and pipe sizes. Standard configurations use the materials listed above for wetted parts in the housing and
closure. Consult factory for availability of other materials.

All Series 4000 sensor electrical components are self-contained. They may be replaced in the field without requiring
recalibration or breakdown of the piping system. Pressure/temperature ratings for the various models are contained in the
Specifications section of this manual. The Series 4000 flow sensor models are summarized in the tables above.

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Series 4000

MECHANICAL INSTALLATION

General

The accuracy of flow measurement for all flow measuring devices is highly dependent on proper location of the sensor in the
piping system. Irregular flow velocity profiles caused by valves, fittings, pipe bends, etc. can lead to inaccurate overall flow
rate indications even though local velocity measurement may be accurate. A sensor locates the pipe where it can be affected
by air bubbles, floating debris, or sediment may not achieve full accuracy, and could be damaged. Badger Meter flow sensors
are designed to operate reliably under adverse conditions, but the following recommendations should be followed to ensure
maximum system accuracy:

1. Choose a location along the pipe where 10 pipe diameters of straight pipe upstream and five pipe diameters of straight
pipe downstream of the sensor provide no flow disturbance. Pipe bends, valves, other fittings, pipe enlargements and
reductions should not be present in this length of pipe.

2. The preferred orientation for horizontal flow is with the curved portion of the sensor housing down. Sensors installed
with the curved portion in the up position could trap air causing inaccurate flow measurement, especially at low flows.
Sensors installed with the curved portion pointing sideways may not only trap air, but increase impeller friction, which
may also affect measurements at low flow rates. Locate sensor to facilitate servicing.

3. 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 should be located to facilitate
servicing. A vertical location may result in reduction of accuracy.

4. Sensors must be mounted in such a way to provide a minimum of 3 inches (75mm) clearance in all directions around
the blue electronics assembly to prevent electro-mechanical interference. This space requirement applies to multiple
4000 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

Ten diameters of straight pipe upstream and five diameters downstream are supplied with the PVC sensor in the form of
attached schedule 80 plain end pipe nipples. Any compatible size and type of fitting or adapter may be connected to the
pipe nipples by thermal or solvent welding. Be sure the fittings and method you choose to install the PVC unit complies with
American Society for Testing and Materials (ASTM) standards. Proper installation has the arrow in the stainless steel cover
pointing the same direction as the flow of the fluid. Do not connect directly to reducing (or enlarging) fittings. An additional
10 diameter upstream and five diameter downstream allowance should be made if this is unavoidable.

Installation of PVDF Sensors

PVDF sensors are supplied with combination end connections. A socket sized to accept most metric sized PVDF pipe may be
used for direct thermal welding. In addition, there is an external thread compatible with George Fisher PVDF union fittings
for use with existing fittings. PVDF flow sensors may also be purchased with George Fischer unions that terminate in metric
dimension sockets, or a wide variety of threaded or flanged connections.

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. Proper sensor orientation is with the arrow on the stainless steel cover pointing in the same
direction as the flow of the liquid. The same ten and five diameter upstream and downstream allowance and orientation
recommendations, as described under Installation for PVC sensors above, must be followed.

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