Badger Meter 7500 User Manual

fi

Coil

DC supply

Electrode

Flow

Liner

Magnetoflow®
Mag Meter

Model 7500P Meter

Installation &

Operation Manual

SCOPE OF THIS MANUAL

This manual contains information concerning the installation,
operation and maintenance of Badger's Magnetoflow® 7500P
Mag Flowmeters. To ensure proper performance of the meters
covered, the instructions given in this manual should be thor­oughly understood. Retain the manual in a readily accessible
location for future reference.

DESCRIPTION AND OPERATION

Badger's 7500P Mag meters are intended for use in fluid
metering applications for process batching in Industrial plants
or concrete operations.

The 7500P Mag meter is a stainless steel flow tube with an
internal isolating lining. Two electromagnetic coils are located
outside the flow tube, diametrically opposed to each other and
protected by a carbon steel housing. Two electrodes, inserted into
the flow tube, are positioned "flush" with the internal diameter of
the tube and perpendicular to the coils. The coils are energized
by a pulsed DC voltage provided by the electronic converter,
and a magnetic field is generated across the flow tube section.
According to Faraday's law, when this magnetic field is "cut"
by the conductive liquid flowing through the meter, a voltage is
generated in the liquid. This voltage is directly proportional to
the liquid flow velocity, and therefore to the actual volumetric

flow rate of the liquid. The electronic converter measures this
voltage, processes the signal, and provides two digital pulse
outputs, scalable to the desired volumetric value. These digital
pulse outputs can be connected to a batch controller, a total­izer display unit for monitoring purposes, or to both devices
simultaneously. Magnetoflow® 7500P operation is not affected
by the presence of suspended solids in the liquid. Variations of
liquid temperature, viscosity or density have no influence in its
principle of operation. A set of convenient, field proven pulse
scaler rotary switches are provided for easy and straight-forward
batch accuracy compensation.

BadgerMeter,Inc.

IOM-075-04

Part No. 53400-075

3-09

UNPACKING AND INSPECTION

To avoid damage in transit, Badger meters are shipped to
the customer in a special shipping container. Upon receipt
of the meter, perform the following unpacking and inspection
procedures. If damage to the shipping container is evident, be
present when the meter is unpacked.

A. Carefully open the shipping container following any instruc­tions that may be marked on the container. Remove all cush­ioning material surrounding the meter and carefully lift meter
from container. Retain the container and all packing material
for possible use in reshipment or storage.

B. Visually inspect the meter for any physical damage such as
scratches, loose or broken parts, or any other sign of damage
that may have occurred during shipment.

NOTE: If damage is found, request an inspection by the car­rier's agent within 48 hours of delivery. Then file a claim with
the carrier. A claim for equipment damaged in transit is the
responsibility of the customer.

STORAGE

If the meter is not to be installed right away, store it in it's original
container in a dry, sheltered location. Storage temperature: -4
to 158°F (-20 to +70°C)

The model 7500P mag is designed to measure flow in one direc­tion only. Carefully observe the "forward flow" label attached

to the meter body and install the meter accordingly.

If horizontal piping orientation is required, the detector should
be mounted in a position at which the electrodes axis will
remain in an horizontal plane (3 and 9 o’clock position; see
figure below).

FIG. 2
HORIZONTAL INSTALLATION
ELECTRODES ORIENTATION

METER INSTALLATION

METER ORIENTATION

Magnetoflow Mag Meters can operate accurately in any pipe
line orientation.

However, the most recommended installation position is vertical
piping, with the the liquid flowing upward.

FIG. 1

VERTICAL PIPE MOUNTING

HIGHLY RECOMMENDED

PIPING CONFIGURATION

Appropriate piping arrangements should be provided to ensure
the meter is not exposed to extreme pipe vibrations. The piping
arrangements should include appropriate pipe supports.

For optimum accuracy performance, it is required to provide
sufficient inlet and outlet straight pipe runs. An equivalent of
3 diameters of straight pipe is required on the inlet side of the
meter, and 2 diameters on the outlet side, measured from the
center of the meter body.

Avoid installing the detector close to flow disturbance generat­ing valves and fittings.

Do not install the detector in the outlet side of Piston or Dia­phragm type pumps. Avoid all pipe locations where the flow
is pulsating. Avoid installing the detector in the suction side
of any pumps; possible creation of vacuum can affect meter
performance or cause damage to the PTFE liner.

TEMPERATURE

Note: Environmental temperature of installation is not to exceed
maximum specification of 122°F (50°) for the meter.

This installation practice ensures two objectives:

· The pipe remains completely full of liquid, even at low flow, low
pressure applications with a discharge to the atmosphere.

· Solid build-ups or sediments that could be part of the pro­cess fluid will not deposit or accumulate on the liner and/or
electrodes.

2

PIPING CONFIGURATION

WRONG

RIGHT

FLOW

FLOW

FLOW

WRONG

FLOW

RIGHT

Protective Grounding Rings

Good Local

Earth Ground

Protective Grounding Ring

(ANY POSITION)

STRAIGHT PIPE RUN

PUMP

CHECK VALVE

NEEDLE VALVE

GLOBE VALVE

(FULLY OPENED)

GATE VALVE

BALL VALVE

TEE

ELBOW

NO PUMPS

ANY VALVE

TEE

NO REQUIREMENT

PIPE REDUCERS

5-7 D

2 D3 D

ELBOW

UPSTREAM

DOWN STREAM

GROUNDING

Proper grounding is vital to ensure a good mag meter opera­tion.

To ensure proper grounding, the 7500P mag meter is provided
with a set of protective grounding rings. The rings also serve
as protection for the liner.

The main purpose of the ground connection is to provide
electrical continuity between the liquid media, the amplifier’s
input ground or zero voltage reference, and a good, solid earth
ground.

PARTIALLY FULL PIPE SITUATIONS

Magnetoflow® meters are designed to operate in closed, full
pipes.

It is relatively common to encounter situations where the pro­cess pipe will remain momentarily partially filled due to certain
hydraulic conditions. Examples of this include discharge to the
atmosphere (lack of back pressure), insufficient line pressure,
gravity flow applications, etc. (see figure above)

To eliminate the negative effect of these situations on the per­formance of Magnetoflow® meters, a few guidelines should
be observed:

· Avoid installing the detector in the highest point of
the pipe line.

· Do not install the detector in vertical, downward flow
sections of the pipe.

· On-Off valves should ALWAYS be located on the
downstream side of the detector.

· Select the recommended vertical orientation when
ever possible.

· Make sure the selected detector size complies with
the application flow rate. Do not oversize pipe line
and detector size.

Connect a grounding strap to a solid, local earth ground (tower
structure or pipe support) (see illustration). It is recommended
to use copper wire, at least gauge AWG 12.

When installing meter, also use standard gaskets to avoid
leaks.

3

ELECTRICAL CONNECTIONS

Ground
Neutral 115 VAC
Hot 115 VAC

Ground

Neutral 115 VAC

Hot 115 VAC

T

2

T

1

BATCH PANEL

Ground
Neutral 115 VAC
Hot 115 VAC

Meter Pulse Input

DC-Switched

Common

Ground

Neutral 115 VAC

Hot 115 VAC

Open Collector
Transistor Output

Solid State

Relay Output

The Magnetoflow® 7500P electronic converter is enclosed in
a water tight (NEMA 4) aluminum enclosure. A pair of 1/2"
NPT water-tight cord grips is provided for the electrical con­nections.

Do not remove these cord grips unless you replace them with
water-tight conduit adapters or similar connectors. Failure to

POWER SUPPLY CONNECTION

comply with this requirement will void the Badger Meter, Inc.
warranty. To access the electrical connection, remove the cover
of the amplifier by loosening the four (4) mounting screws.

For all wiring, use 18 or 20 Awg wire.

CONNECTING MODEL 7500P TO 110 VAC FROM BATCH CONTROL PANEL POWER SUPPLY.

(TYPICAL CONCRETE BATCH PANEL)

• ThisconnectionshownaboveisforBatchPanelsthatrequirea115VAChotpulseformetersignals.

• ItisrecommendedthattheBatchPanelManufacturerbeconsultedtoconrmtherequiredpulsesignal.

• Fora115VACneutralpulsesignaltoBatchPanelsimplytakeT-2Jumperto115neutralpowersupply.

4

WIRING TO PC100 CONTROLLER

T

2

T

1

DC-Switched

Common

PC100 Controller

Open Collector

Tr ansistor Output

1

2

3

45

6

7

8

T

2

T

1

DC-Switched

Common

Open Collector

Tr ansistor Output

Wiring Terminals (ER-8)

For connection of the open collector scaled pulse output from
the Model 7500P to the PC 100 Controller, follow the diagram
below:

WIRING TO ER-8 TOTALIZER / RATE INDICATOR

1. DC Common

2. Count Input - NPN Signal 280 Hz. or Dry Contact 95 Hz.

3. Not Used

4. Remote Reset - Resets count value when switched to common

5. Front Panel Program Enable - Allows access to program mode when connected to common

6. Not Used

7. Not Used

8. DC Supply Input - 10 to 28 VDC for backlighting.

5

CALIBRATION

x0.1 x0.01 x0.001 x0.0001

2

9

6

9

The Model 7500P is provided tested and calibrated with a test
configuration included with each meter when shipped. If reca­libration of your system accuracy may be required, the Model

RECALIBRATION PROCEDURE

If it is necessary to recalibrate the meter, this can be done
by changing the Scale Factor which is set on the four (4)
Rotary Switches located in the upper left hand corner.
(See above figure) To make this change, the following
steps are necessary.

• Determinetheexactquantityofuidthatactually 

passed thru the meter by using a calibrated volumet-
ric container or by weighing the container.

• Notevolumeofuidindicatedbymeter.

• NotepresentScaleFactoron(4)rotaryswitches.

• Usethefollowingformulastocalculatethenew 

Scale Factor for recalibration:

Qty Delivered Old Scale New Scale
Qty on Meter Factor Factor

• Enternewscalefactorontherotaryswitches.

• Rerun test to verify that the recalibration is cor­rect.

EXAMPLE:
You have a 3" size meter in your installation. You run a test
batch quantity of 238 gallons. The totalizer on the meter
indicates 203 gallons. Your present scale factor on the four
(4) rotary switches is .2533.

238

X .2533 (Old Scale Factor) = .2969 (New Scale Factor)

203

X

=

7500P provides a feature, using (4) rotary switches, that permit
a simple re-calibration procedure. (see below)

½" Meter (1-30 gpm) Scaling Factor

1 Pulse Per Gallon .0500

10 Pulse Per Gallon .5000

100 Pulse Per Gallon .5000

500 Pulse Per Gallon .5000

1 Pulse Per Liter .5000

1" Meter (3-80 gpm)

1 Pulse Per Gallon .5000

10 Pulse Per Gallon .5000

100 Pulse Per Gallon .5000

500 Pulse Per Gallon .5000

1 Pulse Per Liter .5000

2" Meter (10-315 gpm)

1 Pulse Per Gallon .2500

10 Pulse Per Gallon .2500

1 Pulse Per Liter .0946

3" Meter (24-690 gpm)

1 Pulse Per Gallon .2533

10 Pulse Per Gallon .2533

1 Pulse Per Liter .1892

4" Meter (40-1200 gpm)

1 Pulse Per Gallon .5000

10 Pulse Per Gallon .5000

1 Pulse Per Liter .1892

6

7500P MAG METER STANDARD SWITCH SETTINGS

1��

0

10��

8

100��

3

1000�

0

½" Meter (1-30 gpm) Pre Selection Factor Jumper Position

1 Pulse Per Gallon 1500 D

10 Pulse Per Gallon 1500 D

100 Pulse Per Gallon 0150 D

500 Pulse Per Gallon 0030 D

1 Pulse Per Liter 3965 D

1" Meter (3-80 gpm)

1 Pulse Per Gallon 6000 D

10 Pulse Per Gallon 0600 D

100 Pulse Per Gallon 0060 D

500 Pulse Per Gallon 0012 D

1 Pulse Per Liter 1585 D

2" Meter (10-315 gpm)

1 Pulse Per Gallon 0750 C

10 Pulse Per Gallon 0075 C

1 Pulse Per Liter 0075 C

3" Meter (24-690 gpm)

1 Pulse Per Gallon 0380 B

10 Pulse Per Gallon 0038 B

1 Pulse Per Liter 0038 B

4" Meter (40-1200 gpm)

1 Pulse Per Gallon 0250 A

10 Pulse Per Gallon 0025 A

1 Pulse Per Liter 0025 A

PRE-SELECTION SWITCHES

On the board diagram on the previous page, note the po­sition of the (4) "Pre-Selection Rotary Switches." As per
the above chart, these switches are set at the factory per
meter size and general magnitude of pulse output desired.
If a change of resolution (pulse output value) is required,
change the Pre-Selection Switches to above values.

Example:
Setting of Pre­selection Rotary
Switch Settings

3" Meter with
1 pulse/gallon = 0380

JUMPERLOCATION

Please note in the illustration the jumper area. There are
(4) jumper positions designated by A, B, C, and D. The

jumper must be located in the correct position for the
respective meter size. The "D" position is for 1/2" and

1" meters. The A, B, and C positions are for 4", 3" and 2"
sizes respectively. See chart above.

7

fi

Copyright © Badger Meter, Inc. 2009. All rights reserved.

Please see our website at

www.badgermeter.com

for specific contacts.

Due to continuous research, product improvements and enhancements, Badger
Meter reserves the right to change product or system specifications without notice,
except to the extent an outstanding bid obligation exists.

BadgerMeter,Inc.

P.O. Box 245036, Milwaukee, WI 53224-9536
Telephone: [phone]
Fax: [phone]

6116 E. 15th Street, P.O. Box 581390, Tulsa, OK 74112
[phone] / Fax: [phone]

www.badgermeter.com