Badger Meter M3000 User Manual

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M-Series® Mag Meter

Model M-3000

Installation &

Operation Manual

IMPORTANT !!!! Read this manual before

attempting any handling or installation of the meter.

IOM-120-05

BadgerMeter, Inc.

53400-120 Rev. 5

9-10

Disclaimer

The user/purchaser is expected to read and understand the information provided in this manual, follow any listed Safety Precautions and Instructions and keep this manual with the equipment for future reference.

The information in this manual has been carefully checked and is believed to be entirely reliable and consistent with the product described. However, no responsibility is assumed for inaccuracies, nor does Badger Meter Incorporated assume any liability arising out of the application and use of the equipment described.

Should the equipment be used in a manner not speciﬁ ed by Badger Meter, Incorporated, the protection provided by the equipment may be impaired.

Questions or Service Assistance

If you have questions regarding the product or this document contact:

Badger Meter, Incorporated P.O. Box 245036 Milwaukee, WI 53224-9536

Telephone: (414) 355-0400, (877) 243-1010

Fax: (866) 613-9305

On the Web: www.badgermeter.com or call your local Badger Meter representative.

Product Identiﬁ cation Information

Record the product identiﬁ cation numbers from the nameplate. Modular Mag Meter Model Number _M-3000______ Serial Number _____________ Tag Number _______________(if applicable)

TABLE OF CONTENTS

Disclaimer ..................................................................................................................................................................................... 2

Questions or Service Assistance................................................................................................................................................ 2

Product Identiﬁ cation Information .............................................................................................................................................. 2

SAFETY PRECAUTIONS and INSTRUCTIONS ........................................................................................................................... 4

Equipment Unpacking, Inspection, Moving and Return Policies .................................................................................................... 4

Rigging, Lifting, Moving Large Units ............................................................................................................................................... 4

Instructions Speciﬁ c to Hazardous Area Installations ............................................................................................................. 5

METER DESCRIPTION .................................................................................................................................................................6

Empty Pipe Detection ..................................................................................................................................................................... 6

Ampliﬁ er Mounting Options ............................................................................................................................................................ 6

Meter Mount ...................................................................................................................................................................................6

Remote Mount ................................................................................................................................................................................ 6

METER/AMPLIFIER LOCATION, ORIENTATION and APPLICATIONS ...................................................................................... 6

Remote Ampliﬁ er Outdoor Location ............................................................................................................................................... 6

Temperature ...................................................................................................................................................................................6

Pipelines and Fluid Flow ................................................................................................................................................................. 7

Meter Orientation ............................................................................................................................................................................ 7

Vertical Placement .......................................................................................................................................................................... 7

Horizontal Placement .....................................................................................................................................................................7

Straight Pipe Requirements ............................................................................................................................................................ 7

Pipe Reducer Requirements ..........................................................................................................................................................7

Chemical Injection Applications ...................................................................................................................................................... 8

Partially Filled Pipe Situations ........................................................................................................................................................ 8

Meter Gaskets and Grounding .......................................................................................................................................................9

METER INSTALLATION ................................................................................................................................................................ 9

Remote Mount Ampliﬁ er ............................................................................................................................................................... 10

Remote Mount Ampliﬁ er/Detector Wiring ..................................................................................................................................... 10

Detector Junction Box...................................................................................................................................................................10

Remote Mount Wiring Diagram .................................................................................................................................................... 11

Electrode and Coil Wiring from Detector Junction Box to Remote Mount Ampliﬁ er Junction Box ................................................ 12

Electrode Wiring .......................................................................................................................................................................... 12

Coil Wiring ................................................................................................................................................................................... 12

Output Wiring ................................................................................................................................................................................ 13

NEMA 6P (IP67) Protection .......................................................................................................................................................... 13

External Disconnect ..................................................................................................................................................................... 16

AC/DC Power Wiring .................................................................................................................................................................... 16

Adjustable Display/Control Card ................................................................................................................................................... 16

AMPLIFIER CONTROLS, CONTROL METHODS AND DATA DISPLAY PROGRAMMING ......................................................17

Card Display and Controls ............................................................................................................................................................ 17

Two Programming Methods .......................................................................................................................................................... 18

Main Screen(s) ............................................................................................................................................................................. 18

Password ...................................................................................................................................................................................... 19

Ampliﬁ er Access Switches/Buttons .............................................................................................................................................. 19

How to Program ............................................................................................................................................................................ 20

What to Program ..........................................................................................................................................................................23

PROGRAMMING REQUIRED PARAMETERS ............................................................................................................................ 23

Input a Password ..........................................................................................................................................................................23

Set Flow Units ..............................................................................................................................................................................24

Set Full Scale Flow ....................................................................................................................................................................... 24

Set Low Flow Cutoff .....................................................................................................................................................................24

Set Flow Direction ........................................................................................................................................................................25

Set Damping Factor ...................................................................................................................................................................... 25

Empty Pipe Calibration ................................................................................................................................................................. 25

Pulse Output ................................................................................................................................................................................. 26

Analog Output ............................................................................................................................................................................... 28

DETECTOR SPECIFICATIONS ................................................................................................................................................... 30

AMPLIFIER SPECIFICATIONS ................................................................................................................................................... 31

MAINTENANCE ........................................................................................................................................................................... 32

Flow Tube and Electrode Cleaning ............................................................................................................................................... 32

Fuse Replacement .......................................................................................................................................................................32

Ampliﬁ er PCB Stack Replacement ...............................................................................................................................................33

FLOW CHART - MENU STRUCTURE ......................................................................................................................................... 35

SAFETY PRECAUTIONS and

INSTRUCTIONS

Safety considerations are emphasized by the placement of safety symbol icons on the product or next to important text, pictures or drawings throughout this manual. The symbols are:

When and where this symbol is attached to the

product it indicates a potential hazard. It means that

documentation must be consulted to determine the

nature of the potential hazard and any actions that need

to be taken.

Warning indicates an action or procedure, which, if not

performed correctly, can result in sever personal injury,

death, or substantial property damage. Comply with the

instruction and proceed with care.

Caution indicates an action or procedure, which if not

performed correctly, will or can cause minor personal

injury or property damage. Comply with the instruction

and proceed with care.

NOTE: Do not remove the liner protector until installation.

8. Storage: If the meter is to be stored, place it in its original container in a dry, sheltered location. Storage temperature ranges are: -4°F to 158°F (-20°C to 70° C).

Rigging, Lifting, Moving Large Units

DO NOT lift or move a meter via its ampliﬁ er, junction box or

cables.

Lift and move meters with ﬂ ow tubes between 2" and 8"

(50 and 200mm) with a crane rigged with soft straps. Place

a strap around the detector body, between the ﬂ anges, on

each side of the detector.

Equipment Unpacking, Inspection, Moving and Return Policies

1. If shipping container damage is evident at delivery, have a responsible person present when the meter is unpacked.

2. Inspect the shipping container for unpacking, lifting or moving instructions.

3. As the unit is opened and unpacked, verify the shipment packing list and your order form match the items in the shipment.

4. Open the container and remove all cushioning materials. Keep the shipping container and packing materials should the meter need to be returned or put in storage.

5. Remove the meter from the container. For meter ﬂ ow tube diameters between 2” and 8” (50 and 200mm) use a crane or lifting device with soft straps placed around the detector body, at the ﬂ anges. For meter ﬂ ow tube diameter sizes 10” (250mm) and larger, lift the unit via the lifting lugs with a crane, cables and hooks.

6. Inspect the meter for signs of shipping damage; scratches, loose or broken parts.

NOTE: If damage is found, a formal claim for damage in transit is the responsibility of the customer. Within 48 hours of delivery request an inspection report from the carrier. File a claim with the carrier. Contact the Badger Meter factory to facilitate repair or replacement, 877-248-1010.

Lift meter ﬂ ow tube diameter sizes 10" (250mm) and larger

via its lifting lugs. Use the proper size crane, cables and

hooks. DO NOT lift the meter by the ampliﬁ er or, on remote

style meter, by the junction box.

7. All detectors with PTFE liners are shipped with a liner protector to maintain proper form of the PTFE material during shipping and storage.

Use the sling-rigged method to lift large detectors into a vertical position while still crated. Use this method to position large detectors vertically into pipelines.

Instructions Speciﬁ c to Hazardous Area Installations

These instructions apply to equipment covered by FM Certiﬁ cate Number IAB-182-01.

1. The temperature range for ﬂ uids passing through the detector is -4°F to +248°F (-20°C to +120°C).

2. The ambient temperature range surrounding the ampliﬁ er is -4°F to +122°F (-20°C to +50°C).

3. The ambient temperature range surrounding the junction box must not exceed 122°F (50°C).

4. During any installation or repair, perform all procedures in accordance with the applicable code of practice.

5. Suitably trained personnel shall perform all installation or repair procedures.

6. If the equipment is likely to come into contact with aggressive substances, it is the responsibility of the user to take suitable precautions that prevent it from being adversely affected, thus ensuring that the type of protection is not compromised.

Aggressive Substances – e.g. acidic liquids or gases

that may attack metals, or solvents that may affect polymeric materials

Suitable Precautions – e.g. regular checks as part of routine inspections or establishing, from the material’s data sheet that it is resistant to speciﬁ c chemicals

Do not lift a detector with a forklift via the detector body between the ﬂ anges. The housing could be dented and/or damage caused to internal coil assemblies.

NEVER place forklift forks or rigging chains, straps, slings,

hooks or other objects inside or through the detector ﬂ ow

tube for lifting or handling purposes. The isolating liner could

be damaged, rendering the unit inoperable.

Additional Information

Certiﬁ cation markings are noted on the product label. Markings include:

Mounted ampliﬁ er 85-240 VAC

Remote mount 85-240 VAC

Mounted ampliﬁ er 24 VDC

Meter Mount Conﬁ guration

The Meter Mount conﬁ guration has the ampliﬁ er mounted directly on the detector. This compact, self-contained conﬁ guration minimizes installation wiring.

Remote mount 24 VDC

For additional information regarding importation, equipment installation, equipment repair, equipment return or renewal parts, please contact:

Badger Meter, Incorporated P.O. Box 245036 Milwaukee, WI 53222 Telephone: (414) 355-0400 Fax: (414) 355-7499 On the WEB:

www.badgermeter.com or contact your local

Badger Meter representative

METER DESCRIPTION

Badger

Model M-3000 electromagnetic meters are FM approved for Class I, Div 2 hazardous locations. To achieve hazardous location ratings electrodes in the ﬂ ow tube are Intrinsically Safe, designed according to Factory Mutual (FM) standards. Those standards limit the amount of energy that can be sent to electrodes to prevent a spark from occurring.

Empty Pipe Detection

Badger Model M-3000 meters are equipped with an Empty Pipe Detection feature. Empty Pipe Detection is accomplished by positioning a third electrode close to the 12 o’clock position. Any time this electrode is not covered by ﬂ uid, for a minimum of ﬁ ve seconds, the meter displays an Empty Pipe Detection condition, sends out an error message if desired, and stops measuring to maintain accuracy. When the electrode is again covered with ﬂ uid, the error message disappears and the meter continues measuring.

Meter Mount

Remote Mount Conﬁ guration Remote Mount conﬁ guration places the ampliﬁ er and its

functions at a location separate from the ﬂ uid ﬂ ow and detector. This conﬁ guration is necessary in situations where process ﬂ uid temperature or environment exceeds ampliﬁ er ratings. A remote mounting bracket is supplied.

Detector and ampliﬁ er are connected by wires, run through conduit, between junction boxes on the detector and remote mounted ampliﬁ er. The distance between the detector junction box and ampliﬁ er junction box can be up to 100 feet (30m).

This conﬁ guration can also provide a more convenient ampliﬁ er programming and display placement for monitoring meter readings.

Ampliﬁ er Mounting Conﬁ guration Options

Two ampliﬁ er-mounting conﬁ guration options are available to meet a variety of meter placement and environmental conditions.

METER/AMPLIFIER LOCATION, ORIENTATION and

Electrode

Plane

RIGHT

Electrode

Plane

WRONG

APPLICATIONS Remote Ampliﬁ er Outdoor Location

The ampliﬁ er can be installed and operated outdoors. However, protection from the elements must be considered:

6. Verify both ends of the signal cables are securely fastened.

7. Place power and signal cables in separate conduit.

8. Place the meter where there is enough access for installation/maintenance purposes.

1. Be aware of the ambient environment and temperature ratings for the unit -4°F to 122°F (-20°C to 50°C).

2. If an indoor location is within 100 feet (30m) of the detector installation, consider increasing the cable length and mounting the ampliﬁ er indoors.

3. At a minimum, fabricate a roof or shield over and/or around the ampliﬁ er to protect the LCD display screen from sunlight.

Temperature

To prevent meter damage in any environment, minimum and maximum temperature ranges must be observed.

1. For remote ampliﬁ er applications, the ﬂ uid temperature range is -4°F to 248°F (-20°C to 120°C) at a maximum ambient temperature of 122°F (50°C) for the following liner materials: PFA, PTFE and Halar

2. For remote ampliﬁ er applications, the ﬂ uid temperature range is 32°F to 178°F (0°C to 80°C) at a maximum ambient temperature of 122°F (50°C) for the following liner materials: Hard rubber and soft rubber.

3. For meter mounted ampliﬁ er applications, the ﬂ uid temperature range is -4°F to 212° (-20°C to 100°C) at a maximum ambient temperature of 122°F (50°C) for the following liner materials: PFA, PTFE and Halar.

4. For meter mounted ampliﬁ er applications, the ﬂ uid temperature range is 32°F to 178°F (0°C to 80°C) at a maximum ambient temperature of 122°F (50°C) for the following liner materials: Hard rubber and soft rubber.

Meter Orientation

Mag meters can operate accurately in any pipeline orientation and can measure volumetric ﬂ ow in forward and reverse directions.

NOTE: A Forward Flow direction arrow is printed on the detector label.

Vertical Placement

Mag meters attain optimal performance when placed vertically, with liquid ﬂ owing upward and meter electrodes in a closed, full pipe.

Vertical placement allows the pipe to remain completely full, even in low ﬂ ow, low pressure applications and it prevents any solids build-up or sediment deposit or accumulation on the liner and/or electrodes.

NOTE: Carefully observe the “Forward Flow” label on the meter body and install the meter accordingly.

5. The ambient temperature range surrounding the ampliﬁ er is -4°F to 122°F (-20°C to 50°C.)

6. The ambient temperature range surrounding a remote junction box mounted to the detector is -4°F to 248°F (-20°C to 120°C.)

Pipelines and Fluid Flow

Pipeline and ﬂ uid ﬂ ow conditions that should be avoided:

1. Do not install the meter where extreme pipe vibrations exist. If vibrations are present, secure piping before and after the meter with appropriate pipe supports. If vibrations can’t be restrained, consider mounting the ampliﬁ er remotely.

2. Avoid installing the detector close to pipeline valves, ﬁ ttings or impediments that can cause ﬂ ow disturbances.

3. For detectors with PTFE liners, avoid installing the detector on suction sides of pumps.

4. Avoid installing the detector on outlet sides of piston or diaphragm pumps. Pulsating ﬂ ow can affect meter performance.

5. Avoid locations near equipment producing electrical interference such as electric motors, transformers, variable frequency, power cables, etc.

Horizontal Placement

In a horizontal piping orientation, mount the detector to piping with the ﬂ ow measuring electrode axis in a horizontal plane (3 and 9 o’clock).

This arrangement prevents solids build-up or sediment deposit or accumulation on the electrodes.

Straight Pipe Requirements

WRONG

FLOWFLOW

FLOW

FLOWFLOW

WRONG

FLOW

Sufﬁ cient straight pipe runs are required at the detector inlet and outlet for optimum meter accuracy and performance. An equivalent of three (3) diameters of straight pipe is required on the inlet (upstream) side. Two (2) diameters are required on the outlet (downstream) side.

CHECK VALVE GLOBE VALVE

BUTTERFLY VALVE

PUMP

ELBOW

TEE

GATE VALVE

(FULLY OPEN)

MINIMUM STRAIGHT PIPE

M-3000 Mag FLOWMETER

FORWARD FLOW

3 x D

MINIMUM STRAIGHT PIPE

7 x D

MINIMUM PIPING REQUIREMENT

STANDARD CONCENTRIC REDUCERS

(NO DISTANCE REQUIRED)

D (Pipe Size)D (Pipe Size)

2 x D

MINIMUM STRAIGHT PIPE

ELBOW TEE ANY VALVE

Pipe Reducer Requirements

With pipe reducers a smaller size meter can be mounted in larger pipelines. This arrangement may increase low ﬂ ow accuracy.

There are no special requirements for standard, concentric, pipe reducers.

Custom fabricated pipe reducers must have an approximate slope angle of 15 degrees to minimize ﬂ ow disturbances and excessive loss of head. If this is not possible, install the custom pipe reducers as if they were ﬁ ttings and install the amount of straight pipe stated previously.

spaced bursts, continuous stream of drips, a liquid or gas can also affect downstream readings by the meter.

Sometimes it’s difﬁ cult to specify the exact downstream placement distances because of the number of variables. Contact Badger Meter Technical Support,

877-243-1010, to

review your application if necessary.

Partially Filled Pipe Situations

It is possible to encounter situations where the process pipe is momentarily only partially ﬁ lled. Examples include; lack of backpressure, insufﬁ cient line pressure, gravity ﬂ ow applications, etc.

To eliminate these situations:

Chemical Injection Applications

For water line applications with a chemical injection point, install the meter upstream of the injection point. This eliminates any meter performance issues.

If a meter must be installed downstream of a chemical injection connection, the recommended distance between the meter and the injection point must be signiﬁ cant; 50 to 100 feet (15 to 30 meters). When the water/chemical solution reaches the meter it must be a complete, homogeneous mixture. If the injection point is too close, the meter senses two (2) different liquids (conductivity is different for each) and correct data output cannot be assured. The injection method:

Do not install the meter in

the highest point of the pipeline

Do not install the meter in a vertical,

downward ﬂ ow section of pipe.

FLOW

FLOWFLOW

RIGHT

ALWAYS locate ON/OFF valves on the

downstream side of the meter

To minimize the possibility of partially full pipe ﬂ ows in horizontal, gravity or low pressure applications, create a pipe arrangement that insures the detector remains full of liquid at all times

To ensure proper unit operation, the mag meter impact ground (zero voltage reference) must be connected to the liquid media and to a good, solid earth ground. Perform grounding procedures after the meter is connected to the pipeline.

Conductive Pipe Grounding

A grounding bolt is located on each mag meter ﬂ ange. Drill and tap the pipeline ﬂ anges on each side of the meter and install a grounding bolt to each.

To ground the unit, attach a ground strap (provided) of copper wire, at least 12AWG size, between the grounding bolts on the meter ﬂ anges and the bolts on the pipeline ﬂ anges. Do this on the inlet and outlet sides of the meter.

Non-Conductive Pipe Grounding

If the process pipeline material is not electrically conductive and your meter was not ordered with an optional grounding electrode, place a grounding ring (available from Badger Meter) between two gaskets on both ends of the meter.

GROUNDING RING INSTALLATION KIT

SUPPLIED HARDWARE INCLUDES: 2 GROUNDING RINGS 4 BOLTS 4 LOCK WASHERS 2 NUTS 2 GROUND STRAPS

Meter Gaskets and Grounding

Two other considerations to meter location, orientation and application are gasket and grounding requirements and placement.

Meter/Pipeline Connection Gaskets

GASKETS RECOMMENDED

Gasket(s) (not provided) must be installed between the detector isolating liner and the pipeline ﬂ ange to ensure a proper and secure hydraulic seal. Use gaskets compatible with the ﬂ uid ﬂ ow. Center each gasket on the ﬂ ange to avoid ﬂ ow restrictions or turbulence in the line.

Do not use graphite or any electrically conductive sealing compound to hold gaskets during installation. Measuring signal accuracy could be affected.

If a grounding ring is used in the detector/pipeline connection, place the ring between two gaskets. (See Non- Conductive Pipe Grounding section.)

After the grounding rings, gaskets and meter are assembled to the pipeline, attach ground straps (provided) of copper

Meter Grounding

Process pipeline material can be either electrically

wire, at least 12AWG size, to grounding bolts on meter ﬂ anges and to the grounding rings.

conductive (metal) or not electrically conductive (made of or lined with PVC, ﬁ berglass or concrete).

If your meter was ordered with an optional grounding electrode, the use of grounding rings is not necessary.

METER INSTALLATION PLANS and EXECUTION

REMOTE MOUNT AMPLIFIER/DETECTOR WIRING

Plan meter layout, location and installation. During installation, remember these important points:

1. Heed all safety notiﬁ cations.

2. Select a detector location with room for installation and maintenance procedures.

3. Use proper lifting, rigging, moving and procedures for large units.

4. Consider the meter environment; particularly ambient and process ﬂ ow temperatures.

5. Consider the process pipeline (vibrations) and its ﬂ ow characteristics (valve and pump locations).

6. Meter orientation to the pipeline (vertical or horizontal).

7. Straight pipe requirements.

8. Pipe reducer requirements.

9. Special applications and/or situations.

For Remote Mount Units consider:

1. Ampliﬁ er location.

2. Remote ampliﬁ er mounting bracket.

3. Proper conduit and conduit ﬁ ttings.

4. Wiring and conduit locations.

REMOTE MOUNT AMPLIFIER

NOTE: Screws are supplied to attach the remote mount

bracket to the ampliﬁ er. Screws are not supplied to attach bracket at mounting location.

Remote Mount Ampliﬁ er Location Requirements:

1. A sturdy and safe mounting surface capable of holding the ampliﬁ er weight (20 pounds, 9 Kg).

2. Within the allowable temperature range: -4°F to 122°F, (-20°C to 50°C).

3. Access to ampliﬁ er covers, ports, terminals, screen and adjustments.

4. As close to the detector as possible.

5. Determine length and route of cable/conduit runs.

Remote Mount Ampliﬁ er

The remote mount ampliﬁ er has three chambers and ﬁ ve wire ports. The Junction Box and Connections Chambers and wiring ports provide ampliﬁ er openings for wire, conduit, tool and hand access to ampliﬁ er terminal blocks. Detector to ampliﬁ er wires connect in the Junction Box Chamber. Ampliﬁ er AC power and customer signal wires attach in the Connections Chamber.

The Display/Programming Chamber provides access to fuses and circuit boards. They are discussed later.

(Refer to the Remote Mount Wiring Diagram on page 11.)

Detector Junction Box

The Detector Junction Box has one chamber and two wire ports. The Junction Box, Chamber and wiring ports provide openings for wire, conduit, tool and hand access to terminal blocks. Detector to remote mount ampliﬁ er electrode and coil wires connect to the detector through the chamber wire ports.

Mount Bracket to Ampliﬁ er

1. Align bracket-mounting holes with ampliﬁ er mounting holes.

2. Attach bracket to ampliﬁ er with supplied screws. Torque screws to 80 in. lb.

2.56

5.12

2.56

.39

3.75

7.50

Mount Bracket/Ampliﬁ er to Location

1. Position the bracket/ampliﬁ er in the desired orientation.

2. Secure bracket/ampliﬁ er to location.

· Suitably trained personnel shall perform all installation or repair procedures.

· Disconnect power to the unit before attempting any installation or maintenance.

· Do not bundle or route signal wires with power wires.

· Use proper conduit, connections and supplied cables in all wiring procedures.

· Observe all local applicable electrical codes when wiring any equipment.

Electrode and Coil Wiring From Detector Junction Box to

Electrode wiring in

detector chamber

Coil Wires

Electrode Wires

Coil Wires

Electrode

wiring in

amplifier

junction box

Remote Mount Ampliﬁ er Juncton Box

A remote mount unit requires electrode and coil cables, from the detector junction box to the ampliﬁ er junction box, be enclosed in properly rated conduit. Use conduit ﬁ ttings (not supplied) that are rated for Class I, Div 2 hazardous locations.

Failure to use proper conduit ﬁ ttings rated for Class I, Div 2 hazardous locations, invalidates the FM rating and any warranties, expressed or implied, for this equipment.

1. Lay out the cable and conduit between the Detector Junction Box and the Ampliﬁ er Junction Box. Use Belden #9155 cable or equivalent for electrodes. Use Belden #8770 cable or equivalent for coils.

2. Run cables through the conduit, between Detector Junction Box and Ampliﬁ er Junction Box.

3. Place four Nema 6P, 1/2 inch NPT ﬁ ttings on conduit.

4. Remove the four junction box wire port screws, two on each junction box.

Electrode Wiring in Detector Junction Box

To connect electrode wires in the Detector Junction Box:

1. Unscrew the Detector chamber cover. If necessary, use a strap wrench.

2. Remove the protective plastic cover to access the terminal block screws.

6. Run cable and conduit to Ampliﬁ er junction box.

Electrode Wiring in Ampliﬁ er Junction Box

To connect the electrode wires in the Ampliﬁ er Junction Box:

1. Unscrew the ampliﬁ er junction box chamber cover. If necessary, use a strap wrench.

2. Remove the protective plastic cover to access the terminal block screws.

NOTE: Plastic cover must be reattached when wiring is complete to maintain hazardous location rating.

3. Strip the cable jacket back 2 inches (50mm).

4. Strip the 4 wires back ¼ inch (6mm).

5. Thread wires through the proper cable access. Connect the wires to the compression style screw terminals of the Ampliﬁ er Junction Box.

NOTE: Plastic cover must be reattached to maintain hazardous location rating.

3. Strip the cable jacket back 2 inches (50mm).

4. Strip the 4 wires back ¼ inch (6mm).

5. Thread wires through the proper cable access. Connect the wires to the compression style screw terminals of the Detector Junction Box.

Red to terminal labeled - E1 Green to terminal labeled - SHLD Black to terminal labeled - E2 White to terminal labeled - EP

Coil Wiring in Detector Chamber

To connect coil wires in the Detector chamber:

1. Lay out the cable and conduit between the Detector Junction Box and the Ampliﬁ er Junction Box. Use Belden #8770 cable or equivalent for coils.

NOTE: Plastic cover must be reattached to maintain hazardous location rating.

2. Strip the cable jacket back 2 inches (50mm).

3. Strip the 2 wires back ¼ inch (6mm).

4. Thread wires through the proper cable access. Connect the wires to the compression style screw terminals of the detector chamber.

Cable length, between Junction Boxes, may be up to 100 feet (30M).

Coil wiring in

detector chamber

Coil Wires

Electrode Wires

4. Connect conduit to junction box. Use a NEMA 6P ½ inch NPT ﬁ tting.

5. Install protective plastic cover over terminal blocks.

6. Attach the ampliﬁ er junction box chamber cover.

Red to terminal labeled – C1 Clear to terminal labeled – C2

5. Connect conduit to junction box. Use a NEMA 6P ½ inch NPT ﬁ tting.

6. Install protective plastic cover over terminal blocks.

7. Attach detector chamber cover.

Cable length between Junction Boxes may be up to 100 feet (30M).

Coil Wiring in Ampliﬁ er Junction Box

To connect the coil wires in the ampliﬁ er junction box:

1. Strip the cable jacket back 2 inches. (50mm)

2. Strip the 2 wires back ¼ inch. (6mm)

3. Connect the wires to the compression style screw terminals of the ampliﬁ er junction box.

OUTPUT WIRING

The Badger

M-3000 Meter converts liquid ﬂ ow into electrical signal(s). With proper output wiring and ampliﬁ er programming, the signal(s) are sent to, and used by, processing equipment used in operations or other procedures.

NOTE: Output wires and terminals are the same for meter mount or remote mount meters

Output wiring requires 18 to 22 AWG maximum, shielded wire (not supplied). Signal wire insulation temperature class should exceed the maximum temperature where installed (typical, 185°F, 85°C).

Use conduit and conduit ﬁ ttings (not supplied) rated for Class I, Div 2 hazardous locations.

NEMA 6P (IP67) Protection

The ﬂ ow meter will fulﬁ ll all the requirements regarding NEMA 6P (IP67) protection if the following points are observed:

Red to terminal labeled – C1 Clear to terminal labeled – C2

Coil Wires

Coil wiring

in amplifie

junction bo

1. For applications with detector mounted ampliﬁ er

(ampliﬁ er is located in submersed location)

• Both screw-on cover gaskets must be clean and undamaged

prior to screwing the covers onto the ampliﬁ er housing.

• Both screw-on covers of the ampliﬁ er housing must be

screwed on tightly (note: hand tightening is sufﬁ cient, over tightening of the cover may result in damage to the covers or the housing.

• The four screws that attach the ampliﬁ er assembly to the

detector neck must be ﬁ rmly tightened.

• Cable glands that are screwed into the NPT connections lo-

cated on the ampliﬁ er housing must be ﬁ rmly tightened.

• Cable glands that are screwed into the NPT connections

located on the ampliﬁ er housing must be approved for NEMA 6P (IP67) service. Additionally, the cable gland must be the correct size for the outside diameter of the cable being used. (note: if the cable gland is not the correct size for the outside diameter of the cable, the gland will not properly seal resulting in water inﬁ ltration).

• All cables must have a “drip loop” to prevent water from

migrating down the cable into the cable gland.

• If a NPT connection is not used, then a plug equipped with

thread sealant that is approved for NEMA 6P (IP67) must be used to ﬁ ll the hole. (note: all three NPT connections of the ampliﬁ er housing come equipped from the factory with hole plugs incorporating approved thread sealant)

• If a conduit connection is required, then the conduit and the

conduit hub must be approved for NEMA 6P (IP67) service.

• All NPT threads must have thread sealant that is approved

for NEMA 6P (IP67) service applied to the threads prior to installation.

2. For applications with remote ampliﬁ er (ampliﬁ er is located in non-submersed location)

• The screw-on cover gasket of the junction box mounted

to the detector must be clean and undamaged prior to screwing the cover onto the junction box housing.

• The screw-on cover of the junction box housing mounted to the detector must be screwed on tightly (note: hand tightening is sufﬁ cient, over tightening of the cover may result in damage to the cover or the housing

• The four screws that attach the junction box assembly to the detector neck must be ﬁ rmly tightened.

• Cable glands that are screwed into the NPT connections located on the junction box housing must be ﬁ rmly tightened.

• Cable glands that are screwed into the NPT connections located on the junction box housing must be approved for NEMA 6P (IP67) service. Additionally, the cable gland must be the correct size for the outside diameter of the cable being used. (note: if the cable gland is not the correct size for the outside diameter of the cable, the gland will not properly seal resulting in water inﬁ ltration).

• All cables must have a “drip loop” to prevent water from migrating down the cable into the cable gland.

• If a NPT connection is not used, then a plug equipped with thread sealant that is approved for NEMA 6P (IP67) must be used to ﬁ ll the hole. (note: both NPT connections of the junction box housing come equipped from the factory with hole plugs incorporating approved thread sealant).

• If a conduit connection is required, then the conduit and the conduit hub must be approved for NEMA 6P (IP67) service.

• All NPT threads must have thread sealant that is approved for NEMA 6P (IP67) service applied to the threads prior to installation.

NOTE: Use twisted pair shielded wire for all output wiring. Belden #1266A or equivalent.

Ampliﬁ er Output Wire Terminal Block Connections:

Reference Control Signal Wiring Diagrams on next two pages.

All of the above points must be strictly followed for NEMA 6P (IP67) service. Failure to comply could possibly result in an electrical hazard and/or damage to the ﬂ ow meter.

Output Wire Connections

· Properly trained personnel must perform all

installation and/or repair procedures.

· Disconnect power to the unit before attempting any

installation or maintenance.

To connect control signal wires:

1. Remove the connections chamber cover. If necessary,

use a strap wrench.

2. Remove the two terminal block wire port access screws.

3. Connect output wires to processing equipment.

4. Group and place output wires in conduit. Position conduit

at ampliﬁ er terminal block wire ports.

5. Connect conduit to control output signal wires ports.

6. Run output wires through wire ports, into ampliﬁ er

terminal chamber.

7. Strip output wires back ¼ inch (6mm).

8. Connect output wires to terminals (see below).

Terminal 1 +18V DC – Function: 50mA max supply

Terminal 2 input 1 (+) – Input – Functions: reset, positive zero return

Terminal 3 Output 1 (+) – Programmable Passive output to

Badger

external counter Functions: forward pulse, AMR pulse, ﬂ ow set point, error alarm, empty pipe, ﬂ ow direction Active Output to external counter

Terminal 4 – Commom ﬁ eld ground

Terminal 5 – Output 2 (+) – Programmable transistor

output – Passive output to Badger

external counter Functions: reverse pulse, frequency output, preset output, ﬂ ow set point, error alarm, ﬂ ow direction Active output to external counter

Terminal 6 – Ground from external counter device

• Output 2 Transistor Output (open collector) 24VDC Max .5W Max

Passive Output

Functions: Reverse (only) Pulse Frequency Output Preset Output Flow Set Point Error Alarm Flow Direction

}

Programmable

Output 2 (+) 5

Common 6

—

External Counter Badger Meter ER8 or AMR Device

Active Output

Output 2 (+) 5

Common 6

External Counter

0 +

0 —

+18VDC 1

10k Resistor (Not Supplied)

• Output 4 Solid State Relay Output 24V AC/DC Max 500mA Max

Output 4 (+) 15

Output 4 (-) 16

+24VDC

—

Alarm

Indicator

Functions: Preset Output Flow Set Point Error Alarm Empty Pipe Error Flow Direction

connected to terminal 5

Terminal 7 – RS485 A –

Terminal 8 – RS485 B –

Terminal 9 – Analog Output –

Terminal 10 – Common ﬁ eld ground

Terminal 11 – RS232 OUT –

Terminal 12 – RS232 IN –

Terminal 13 – Output 3 (+) Solid state relay output

Functions: preset output, ﬂ ow set point, error alarm, empty pipe error, ﬂ ow direction

Terminal 14 – Output 3 (-)

Terminal 15 – Output 4 (+) – Solid state relay output

Functions: preset output, ﬂ ow set point, error alarm, empty pipe error, ﬂ ow direction

Terminal 16 – Output 4 (-)

Auxiliary Input Wiring Diagram

+18VDC 1

Input 1 (+) 2

Common 4

Function: Reset Positive Zero Return

Normally Open Contact

5-24VDC

_____________________________________________

• Output 3 Solid State Relay Output 24V AC/DC Max 500mA Max

Output 3 (+) 13

Output 3 (-) 14

Functions: Preset Output Flow Set Point Error Alarm Empty Pipe Error Flow Direction

+24VDC

—

Alarm

Indicator

_____________________________________________

External Disconnect

Analog Output Wiring Diagrams

• Analog Output (Loop voltage = 18VDC Sourced, 750 MAX)

mA Analog Output (+) 9

Common 10

_____________________________________________

• Output 1 Transistor Output (open collector) 24VDC Max .5W Max

Passive Output Wiring

Active Output Wiring

_____________________________________________

Functions: Forward (only) Pulse AMR Pulse Flow Set Point Error Alarm Empty Pipe Flow Direction

Output 1 (+) 3

Common 4

+18VDC 1

Output 1 (+) 3

Common 4

—

10k Resistor (Not Supplied)

External Counter

Badger Meter ER8 or AMR Device

0 +

0 —

Function: 4-20mA 0-20mA 0-10mA

External Counter

Programmable

}

Position this device in an accessible location.

Position and identify the disconnect device so as to provide safe and easy operation.

Label the disconnect device as being for the Mag Meter.

Install an external disconnect switch or circuit breaker that meets local standards.

AC/DC Power Wiring

For AC/DC power use three wire, sheathed, cable with cable diameter of 18 AWG (not supplied).

AC/DC wire insulation temperature class must not exceed the maximum ambient temperature of its location.

Use conduit and conduit ﬁ ttings (not supplied) that are rated for Class I, Div 2 hazardous locations. To maintain a NEMA 4X rating, use watertight ﬁ ttings that are rated NEMA 4X or better.

Amplifier AC wires

and

terminal

Black to L White to N Green to G

85-265 VAC

45-65 Hz

Amplifier DC wires

and

terminal

Positive to + Negative to –

–

22-26 VDC

To re-position or rotate the display/control card in the ampliﬁ er:

To prevent accidents connect main power only after all other wiring has been completed.

The ampliﬁ er is a microprocessor device. It is important that the power supply be as “clean” as possible. Avoid using power lines that feed heavy loads; pumps, motors, etc. If dedicated lines are not available, a ﬁ ltering or isolation system may be required.

Power wiring is the same for meter mount and remote mount ampliﬁ ers.

1. Remove the Wire Port cover from ampliﬁ er connections chamber.

2. Lay out power cable and conduit to ampliﬁ er.

3. Place cable in conduit.

4. Strip cable back 2 inches (50mm).

5. Strip wires back ¼ inch (6mm).

6. Attach wires to ampliﬁ er 6a. For AC wiring: terminal.

1. Remove display chamber cover. Turn the cover counterclockwise to remove it from the ampliﬁ er. If necessary, use a strap wrench.

2. Remove the 2 card screws and washers. (NOTE: Use a split screwdriver to prevent dropping screw into enclosure.)

6b. For 24VDC wiring:

7. Connect conduit to ampliﬁ er.

8. Attach chamber cover.

Adjustable Display/Control Card

Because meter positioning sometimes places the ampliﬁ er display/programming chamber in an awkward position, the display/control card is adjustable in 90-degree increments.

Disconnect main power to the unit before attempting any device maintenance.

3. Tilt card up/out approximately 45 degrees at the holding clips.

4. Gently pull card down and out from between holding clips.

5. Rotate card to appropriate position.

6. Angle card and position card holes between the holding clips.

7. Push card in, between holding clips. Lower card back into position and attach card with screws and washers.

8. Attach the chamber cover.

AMPLIFIER CONTROLS, CONTROL METHODS and DATA DISPLAY PROGRAMMING

The M-3000 ampliﬁ er display/programming chamber contains a display/control card. This card and its display screen provide easy access to meter information and the ability to view, program and adjust meter data parameters.

Card Display and Controls

The M-3000 uses a 2.5 X 1 inch (63 X 25mm) four line, 16character, backlit, LCD display.

Display screens and screen data are manipulated with magnet switches or push buttons. By operating the switches or buttons different screens are accessed, program parameters are selected and changed and settings are reprogrammed.

If no contact is made with switches or buttons for 2 minutes, in any parameter, the display returns automatically to the Main Screen.

ACCESS to AMPIFIER SCREENS, DATA and PARAMETER PROGRAMMING NOTE: The M-3000 can be programmed to meter many

ﬂ ow situations and serve a variety of purposes during a production process. To meet diverse needs there are a wide variety of programming options and parameters. Your metering requirements probably do not require the use of all program screens, options and parameters.

Your M-3000 ampliﬁ er is delivered preprogrammed, based on information available at the time the unit was ordered. In most instances it will not require any changes.

Use this section to program ﬂ ow signal outputs or reprogram your meter to speciﬁ c requirements.

Flow measurement and totalizing continues during ampliﬁ er programming.

Two Programming Methods

There are two methods for programming.

In one method a magnet wand is used to manipulate +, and E switches to view and change screens and program functions and settings. The ampliﬁ er display chamber cover stays on.

Both main screens display the rate of ﬂ ow (R=) and ﬂ ow units).

Uni-Directional Flow Main Screen

Uni-directional Flow totalizes pipe ﬂ ow in only one direction, the ﬂ ow direction arrow printed on the detector label. (reference page 25, "Set Flow Direction" to program for unidirectional mode)

Uni-directional readings, on the main display screen, are identiﬁ ed as R=, T1, T2 and PS.

R= Flow Rate

T1 registers Forward Volume T2 registers Forward Volume and can be reset through Input

The other method involves removing the display chamber cover and manipulating the +, - and E push buttons to view and change settings and program desired meter functions and settings.

AMPLIFIER SCREENS, MENUS and PROGRAMMING

Ampliﬁ er programming requires planning, moving and activating the +, - and E selections on three types of menu/ parameter screens, List screen, Input Numbers screen and select ON or Off screen.

MAIN SCREEN(S)

The ﬁ rst screen is the Main Screen. It is always displayed when programming functions are not occurring.

NOTE: When programming, if no contact is made with switches or buttons for 2 minutes, in any parameter, the display returns automatically to your programmed Main Screen.

PS registers Preset Batch Amount

With this information an operator can tell at a glance the volume going through the meter.

Bi-Directional Flow Main Screen

Bi-Directional Flow totalizes pipe ﬂ ow in both directions (reference pag

Directional Mode)

Bi-directional totalizers readings, on the display screen, are identiﬁ ed as R=, T+, T- , TN and PS.

R= Flow Rate T+ registers Forward Volume T- registers Reverse Volume

e 25, "Set Flow Direction" to program for Bi-

Tw o Main Screen Format settings are possible. Which setting to use is determined by the ﬂ uid Flow Direction through your meter. The settings are Uni-Directional ﬂ ow or Bi-Directional ﬂ ow (reference page 24, "Set FLow Rate Unit of Measure and Set Totalizer Unit of Measure" to porgram ﬂ ow units).

TN Net Total = (T+) - (T-) PS registers Present Batch Amount

With this information an operator can tell at a glance the volume going through the meter in both directions.

PASSWORD ENTRY

With your Main Screen showing on the display, switch or press E. Screen PASSWORD??? 01 opens.

PASSWORD??? 01 is a typical Input Numbers screen.

If a password has been entered into your program, this screen opens (reference page 23, "Input a Password" for programming a password).

An underscore ( _ ) is positioned under the ﬁ rst 0.

1. Switch or press + to increase the number by one

digit. Switch or press - to decrease the number by one digit.

Switch/Buttons (+ and -)

2. After the correct number is entered for that digit,

press E to move the underscore to the next 0.

3. Repeat the number selection process for this and

all the 0’s.

4. After the last number is entered, press E.

5. The MAIN MENU appears.

However, if the wrong password was entered: Screen INVALID PSWD 02 opens.

1. Select +, - or E to return to the Main Screen.

Select/Press + to:

· move text up by one line, relative to the on screen arrow, for each select/press when choosing menu or sub-menu list names

· move text up by one line, relative to the arrow, for each select/press when selecting a parameter setting from a list

· increase a number by one digit for each select/ press when inputting parameter numeric settings

Select/Press – to:

· move text down by one line, relative to the on screen arrow, for each select/press when choosing menu or sub-menu list names

· move text down by one line, relative to the arrow, for each select/press when selecting a parameter setting from a list

· decrease a number by one digit for each select/ press when inputting parameter numeric settings

E Switch/Button

2. Press E again.

3. The screen returns to PASSWORD??? 01. Enter the correct password as described above.

All passwords are factory set to 0000 (no password is programmed or required). If 0000 is the password, pressing E from the Main Screen opens the MAIN MENU screen.

Ampliﬁ er Access Switches/Buttons

Accessing ampliﬁ er menus, movement to and between screens, parameter selections and settings are all accomplished by pressing the +, - and E magnet operated switches or push buttons in conjunction with an on-screen location arrow.

Select/Press E to:

· To enter (open) a menu or sub-menu topic at which the arrow is pointing.

· Select between ON/OFF parameter settings for each select/press.

· Move the parameter numeric setting underscore ( _ )one place to the right for each select/press when inputting parameter numeric settings.

· SAVE a parameter numeric setting. After all numbers are input, press E and the setting is saved, the screen closes and the previous screen with the arrow pointing at "Exit this Menu" shows again. Select E again. That screen closes and the previous screen appears with the arrow pointing at its “Exit this Menu”.

· Continue selecting E to return to the Main Screen.

MAIN MENU 00

--------------->Exit this Menu Meter Setup Measurements Inputs/Outputs Clear Totals Communications Info/Help Logout

MAIN MENU 00

--------------->Exit this Menu Meter Setup Measurements Inputs/Outputs Clear Totals Communications Info/Help Logout

· If your ampliﬁ er is not password protected, pressing E from the Main Screen accesses the MAIN MENU. The MAIN MENU is a list that provides access to all ampliﬁ er menus and parameters.

· If your ampliﬁ er is password protected and E is pressed from the Main Screen, the PASSWORD screen opens (reference PASSWORD??? 01, below).

How to Program

Ampliﬁ er screens, menus and program parameters are arranged in the familiar “branching” format where the MAIN MENU screen is a list of selections. The Main Menu list provides access to other lists, selections or parameter screens which provide input for meter programming.

MAIN MENU

The MAIN MENU contains a list of eight selections and an “Exit this Menu” choice. All ampliﬁ er programming and parameters are accessed from this list.

The ampliﬁ er program uses three types of screens; a List screen, an Input Numbers screen and a select ON or Off screen.

Sample List Screen

Sample Input Numbers Screen

Only four lines of text are visible on the display screen. Operating the + and – switches/buttons moves text up or down and into view.

When an item from the list on the MAIN MENU is selected, (press E when the item is in line with the arrow) either a screen opens that requires an action such as select a size or numeric unit for a parameter, turn a parameter on or off, etc. or a screen with another list may open requiring another selection be made to access and set a speciﬁ c parameter size, numeric unit or on/off conﬁ guration.

Each screen has a name and number that displays at the top of the screen. Write down screen names, numbers and parameters that you access and change should other changes be needed later.

NOTE: Your metering requirements may not require the use of all screens, options and parameters.

MAIN MENU 00 is a typical List screen. It provides access to parameter screens.

The MAIN MENU is a list of eight selections and an “Exit this Menu” choice. All ampliﬁ er programming and parameters are accessed from this list.

Sample Select ON or OFF Screen

The following pages introduce you to the screen formats, describe how to maneuver to and through them and provide some speciﬁ cs about programming terminology and parameters.

If possible, have access to your ampliﬁ er display and controls and perform these screen manipulations.

1. Press + or – to position the arrow at a selection.

2. For example, press + once to place the arrow at Meter Setup.

3. Next, press E.

PIPE DIA. 11

-------------- Exit this Menu 6mm [1/4"] 8mm [5/16"] 10mm [3/8"] 15mm [1/2"] 20mm [3/4"] 25mm [1 "] 32mm [1 1/4"] 40mm [1 1/2"] 50mm [2"] 65mm [2 1/2"] 80mm [3"] 100mm [4"] 125mm [5"] 150mm [6"] 200mm [8"] 250mm [10"] 300mm [12"] 350mm [14"] 400mm [16"] >450mm [18"] 500mm [20"] 550mm [22"] 600mm [24"]

4. Screen METER SETUP 10 opens.

METER SETUP 10 is another List screen it provides access to common meter parameters.

1. Maneuver the + or – magnetic switches or push buttons to position the arrow at a selection.

2. For example, place the arrow at Pipe Dia. by pressing or activating + button once.

PIPE DIA. 11 is a list of pipe diameter sizes.

3. Press E to open the Pipe Dia. screen.

4. Screen Pipe Dia. 11 opens.

PIPE DIA. 11 is another List screen. It requires a parameter selection.

5. Press + or – to position the arrow at the appropriate pipe size.

6. Press E.

7. A screen, with the statement [(xx mm [xx”] ] **SELECTED** appears for about 2 seconds.

It veriﬁ es that the selected pipe diameter size parameter was entered into the ampliﬁ er settings.

8. The screen automatically returns to METER SETUP 10 with the arrow pointed at Exit this Menu.

6. Press E.

Transitions

1. Press + or – to position the arrow at another selection or E to return to the Main Menu.

2. Use the E key to return to screen Main Menu 00.

3. Next, press + three times to position arrow at Inputs/ Outputs.

4. Press E.

7. Press + once to move the arrow across from Pulses / unit.

8. Press or activate E.

Pulses / Unit 3D is a typical Input Numbers screen.

1. When the screen opens, the arrow is pointing at a number.

2. Use + or – selections to increase or decrease the underscored number to the desired digit.

3. Select E to move the underscore to the next digit and repeat the number selection process.

4. To skip a digit press E. The underscore moves to the next digit.

5. When all digits are set, press E. Pulses / Unit 3D is programmed into the system and the screen Dig Output 1 33 returns.

5. Press + three times to position arrow at Digital Out. #1 on screen In/Outputs 30.

Empty Pipe is a “branch” list screen from the MAIN MENU. From here calibrate ON or OFF is made.

1. Press E to activate the Main Menu 00 screen.

2. Press the + once to place the cursor at Meter Setup.

3. Press E to bring up Meter Setup 10 screen.

4. Press + ﬁ ve times to position the cursor at Empty Pipe.

5. Select or press E.

6. Screen Empty Pipe 15 opens.

Empty Pipe 15 is a typical select ON/OFF screen.

Input a Password

1. With Main Screen up, press E, to open MAIN MENU 00.

2. With MAIN MENU 00 up, press + once to move cursor to Meter Setup. Press E.

Empty Pipe is shipped OFF. To turn Empty Pipe, On:

1. Press + once to move the cursor down one place, to Cal. empty pipe.

2. Press E.

3. In screen EMPTY CALIB. 1E, press + twice.

4. Press E to turn Cal=[ON].

5. Press + to move cursor to Exit WITH save.

6. Press E to lock the selection into the program.

Continue pressing E to reverse through the screens to your next programming selection or to return to the Main Screen.

You have now used the +, - and E selections to access the three types programming screens, List, Input Numbers and Select ON or Off and maneuver through some meter programming.

3. On METER SETUP 10 screen, press + six times or - once to go to Chg. Password.

4. At CHG. PASSWORD 16 screen, input a password number.

5. Or this screen comes up. Input the correct password.

6. If the wrong number is input, INVALID PSWD comes up. Press +, - or E once.

What to Program

There are a variety of screens available. Refer to the "Flow Chart - Menu Structure" on page 35 for all programming options.

PROGRAMMING REQUIRED PARAMETERS

All meters have required parameters that must be programmed. They include a Password (if desired), the Main

Screen for Uni-or Bi-Directional Flow, Empty Pipe, Pulse Output and Analog Output, among others.

This section presents keystroke details describing how to program required parameters.

7. Main Screen appears. Press E again.

8. PASSWORD??? 01 screen reactivates. Input the correct password.

7. From TotalizerUnit 22 press + or - to select a totalizer unit. Press E.

Set Flow Rate: Unit of Measure and Totalizer - Unit of

Measure

1. With Main Screen up, press E.

2. With MAIN MENU 00 active, press + twice (Measurements) and then E.

3. On the MEASUREMENTS 20 screen press + once to place cursor at Flow Unit. Press E.

8. This type of screen shows for two seconds.

9. Screen goes back to MEASUREMENTS 20.

Set Full Scale Flow Rate Value

1. Press + three times to move the cursor to FullScaleFlow. Press E.

2. At FullScale Flow 23 input the proper ﬂ ow. Select E to move cursor as described earlier.

4. From FLOW UNITS 21 press + or - to select a ﬂ ow unit. Press E.

5. This type of screen shows for two seconds.

6. The screen returns to MEASUREMENTS 20. With the cursor at Exit this Menu, press + twice to move cursor to Totalizer Unit. Press E.

3. Screen returns to MEASUREMENTS 20.

Set Low Flow Cutoff

1. Press + four times, to place cursor at LowFlow CutOff. Press E.

2. At LowFlowCutOff 24 screen input a percentage at the arrow. Press E.

Set Flow Direction

1. At MEASUREMENTS 20 press + ﬁ ve times to set the arrow at Flow Dir. Press E.

2. At FLOW DIR 25 press + or - to select Uni-Directional or Bi-Directional.

3. This type of screen shows for 2 seconds.

5. MEASUREMENTS 20 screen returns with the arrow pointing at Exit this Menu.

6. Press E once to place cursor at Main Menu 00.

7. Press E once to move cursor back to the Main Screen.

Set Damping Factor

1. At MEASUREMENTS 20 press + six times to move the arrow to Damping Factor. Press E.

2. At DampingFactor 26 press Exit this Menu, No Damping or press a Time Frame.

3. If No Damping is selected, this type of screen shows for 2 seconds.

Empty Pipe Calibration

1. Press E once to move to Main Menu.

2. In the MAIN MENU 00, select Meter Setup.

3. In METER SETUP 10, select Empty Pipe.

4. And this type of screen shows for 2 seconds when Damping Factor time is selected.

4. In EMPTY PIPE 15, select Cal. empty pipe. Next, press E.

5. Select Cal[OFF] E=ON, press or select E once to change OFF to ON. (NOTE: Make sure the Flow Detector Pipe is Empty.)

12. In EMPTY CONTROL 1G, press + twice to move cursor to Det[OFF] E=ON. Press E once to switch OFF to ON.

NOTE: With the pipe empty the usage reading should be between 3.00 and 3.30 Volts.

6. Select Exit WITH save. Press E once to save the setting and return to EMPTY PIPE 15.

7. In EMPTY PIPE 15, select Cal. full pipe. Then, press E.

9. Select Cal[OFF] E=ON, press or select E once to change to OFF to ON.

is full of ﬂ uid.)

(NOTE: Make sure the Flow Detector pipe

13. Press + once to move cursor to Exit WITH save. Press E once to save the setting and return to EMPTY PIPE 15.

Pulse Output

1. Press E once to move cursor to Main Menu.

2. In the MAIN MENU 00, press + three times to move the crusor to Inputs/Outputs. Next, press E.

NOTE: The full pipe voltage reading should be below

3.00 Volts.

10. Press + once to move cursor to Exit WITH save. Press E once to save the setting and return to EMPTY PIPE 15.

11. In EMPTY PIPE 15, press + three times to place cursor at Enable/Disable. Next, press E.

3. At IN/OUTPUTS 30 press + three times to place the cursor at Digital Out. #1. Press E.

4. In DIG OUTPUT 1 33, press + once to move the cursor to Pulses / unit. Press E.

You only need to do this if the function of output one (1) is to be Fwd Pulse or AMR (50ms pulse.) (Refer to page 36 "Digital Out #1.")

5. In PULSES/UNIT 3D input a proper number as described earlier. Press E.

6. The screen returns to DIG OUTPUT 1 33. Press or activate + twice, then press E.

NOTE: When the ﬂ ow rate exceeds the set point max. value (entered as a percentage of full scale ﬂ ow) the output activates.

This is only for Fwd Pulse. (Refer to page 36 - "Digital Out #1.")

7. Into screen PULSE WIDTH 3E enter a number. Press E.

8. The screen returns to DIG OUTPUT 1 33. Press + three times, then press E.

SET POINT

This is only for Flow Set Point. (Refer to page 36 - "Digital Out #1.")

This is only for Flow Set Point. (

Out #1.")

OUTPUT TYPE

1. Press or activate the letter E to return to screen DIG OUTPUT 1 33.

2. In DIG OUTPUT 1 33 press + ﬁ ve times, to Output Type.

3. In OUTPUT TYPE 3H press Normally Open or Normally Closed.

•

Select N.O. or N.C. for any output. (Refer to page 36, "Digital Output #1.")

Refer to page 36 - "Digital

1. Into screen SET PT. MIN 3F enter a number.

NOTE: When the ﬂ ow rate falls below the minimum set point

value (entered as a percentage of full scale,) the output activates.

2. The Screen returns to DIG OUTPUT 1 33. Press + four times, then press E.

3. In SET PT. MAX 3G enter a number.

• Normally Opened or Closed **Selected** shows for two seconds.

• The screen goes back to DIG OUTPUT 1 33.

4. Pres + six times, or - once to Select Function.

5.When Select Function is selected, screen Z1 appears for two seconds.

6. It then switches to SELECT OUT #1 3J. Make a selection. Press E.

7. This type of screen shows for two seconds and then returns to DIG OUTPUT 1 33.

3. At IN/OUTPUTS 30 press + once to place the cursor at Analog Output. Press E.

4. In ANALOG OUTPUT 31 press + once to move the cursor to Range Select. Press E.

5. In RANGE SELECT 3A select a range with the + button

and then press E.

Whichever selection is made from screen SELECT OUT #1 3J, the next screen always shows XXXXX ** SELECTED**.

The screen then returns to DIG OUTPUT 1 33 where you will

have to:

1. Select Functions screen

2. Screen Z1 appears

3. Select another screen Do this until all required Digital Outputs are programmed.

There are four Digital Outputs in this program. Perform the same for all of them, if applicable. (Note that not all output functions are available on all outputs.)

Analog Output

1. Press E once to move cursor to Main Menu.

6. The screen returns to ANALOG OUTPUT 31. Press + twice to move the cursor to Zero Calibrate and then press E.

Connect amp meter to mA analog output pins 9 and 10.

7. In ANALOG ZERO 3B make a selection of Decrease or Increase based on what the amp meter is reading.

8. Press the E button until the amp meter reads the desired

No Flow set point. (The line to the left of the selection rotates as the E button is pressed, to show that there is activity.)

2. In the MAIN MENU 00, press + three times to move the cursor to Inputs/Outputs. Next, press E.

9. Press + to set at Exit WITH save.

10. Press E to Save.

11. After pressing E, the menu goes back to ANALOG OUTPUT 31. Press + three times to place arrow at FS Calibrate. Press E once.

12. Screen ANALOG FS CAL 3C comes up. Press + to set the arrow across from Decrease AO or Increase AO. Press E button until amp meter reads the desired Full Scale Set-point.

17. MAIN MENU 00 returns with the arrow pointing at Exit this Menu. Press E.

18. The screen returns to the Main Screen.

The above programming sequence guided you through various screens and programming. These are the basic features that need to be programmed initially. Please refer to the programming ﬂ ow chart located on pages 35-37 for all of the programming options.

13. Press + to set screen at Exit WITH save.

14. Press E to Save.

15. ANALOG OUTPUT 31 returns with the arrow pointing at Exit this Menu. Press E.

16. IN/OUTPUTS 30 returns with the arrow pointing at Exit this Menu. Press E.

7.52"

191mm

5.20"

132mm

7.22"

183mm

5.47"

139mm

9.20"

234mm

3.73"

95mm

3.54"

90mm

4.25"

108mm

7.42" 188m

0 C

SIZE

M-3000 Meter Mount Ampliﬁ er on Detector M-3000 Remote Mount Junction Box on Detector

SPECIFICATIONS

Flow Range: 0.1 to 39.4 ft/s (0.03 – 12 m/s) Flow Direction: Uni-directional or Bi-directional Sizes: 1/4" to 24" (6 to 600mm) Conductivity: Min. 5 micromhos/cm Accuracy: ± 0.25% of rate for velocities greater than 1.64 ft/s

(0.50 m/s) ± 0.004 ft/s (± 0.001) m/s) for velocities less than

1.64 ft/s (0.50 m/s) Electrode Materials: Alloy C, 316 stainless steel, gold/platinum plated, tantalum, platinum/rhodium Liner Material: PFA from 1/4” to 3/8" (6 to 10mm), PTFE from 1/2" to 24" (15 to 600mm), soft and hard rubber from 1" to 24" (25 to 600mm),

Halar

from 12" (300mm) to 24" (600mm)

NSF Listed:

Models with hard rubber liner, 4-inch and larger PTFE liner - all sizes

Fluid Temperature:

With remote mounted ampliﬁ er PFA, PTFE & Halar: -4°F to 248°F (-20°C to 120°C) @ Max. ambient temp. of 122°F (50°C) Soft & Hard rubber: 32°F to 178°F (0°C to 80°C) @ Max. ambient temp. of 122°F (50°C)

With meter mounted ampliﬁ er PFA, PTFE, & Halar: -4°F to 212°F (-20°C to 100°C) @ Max. ambient temp. of 122°F (50°C) Soft & hard rubber: 32°F to 178°F (0°C to 80°C) @ Max. ambient temp. of 122°F (50°C)

Coil Power: Pulsed DC Pipe Spool Material: 316 stainless steel Spool Housing Material: Carbon steel, welded - NEMA 4X/6P (IP66/

IP67). Tested at 1.8m (6 feet) for 24 hours. Junction Enclosure Material: (for remote mounted ampliﬁ er option) Cast Aluminum (powder coated paint), NEMA 4X/6P (IP66/IP67). Tested at 1.8m (6 feet) for 24 hours.

Flanges: Carbon Steel or 316 stainless steel (ANSI B16.5 Class 150 RF) Grounding Rings (optional, 2 required) : 316 stainless steel

Meter Size Thickness (one ring) 1/4" to 10" (6 to 250mm) .135" (3.43mm) 10" to 24" (250 to 600mm) .187" (4.75mm) Grounding Electrode (optional): Alloy C, 316 stainless steel, gold/platinum plated, tantalum, or platinum/rhodium Electrical Classiﬁ cation: FM approved for Class I, Div 2 Groups A-D, Class II, Div 2 Groups F&G - CSA Certiﬁ ed

Pressure Limits: Max. 150 psi (10 bar) Ambient Temperature: -4°F to 122°F (-20°C to 50°C) Locations: Indoor and outdoor Altitude: Maximum 6500 feet (2000m)

AMPLIFIER SPECIFICATIONS

Detector Mount Ampliﬁ er Remote Mount Ampliﬁ er

SPECIFICATIONS

Junction Box

on Detector

Power Supply: AC or optional 24VDC AC Power Supply - 85-265VAC 45-65Hz

Voltage Fluctuation = ± 10% of nominal Over Voltage = Catagory II Power Consumption = 20W DC Power Supply - (optional) + 24VDC ±10% 8W Accuracy: ± 0.25% of rate for velocities greater than

1.64 ft/s (0.50 m/s)

± 0.004 ft/s (± 0.001 m/s) for velocities less than 1.64 ft/s (0.50 m/s)

Repeatability: 0.1% of rate Flow Range: 0.10 to 39.4 ft/s (0.03 to 12 m/s) Fluid Conductivity: Min. 5.0 micromhos/cm Flow Direction: Unidirectional or bidirectional (programmable) Totalization: 3 separate displayable totalizers – 10 digits

(programmable - forward, reverse and net) Analog Outputs: 0-10mA, 0-20mA, 4-20mA (programmable and scalable). Voltage sourced (18VDC) – isolated. Max. loop resistance = 750 Ω Frequency Output: Open Collector – Max. full scale ﬂ ow = 10Khz Digital Outputs: (2) Open collector, (programmable – scaled pulse, ﬂ ow alarm, status, or frequency output) Max. 24VDC, 0.5W (2) AC solid state relay (programmable – ﬂ ow alarm or status). Max. 24VDC@0.5A Communication: RS232C serial, standard ANSI terminal compatible data stream Pulse Width: Open Collector, 5ms to 1 second (programmable) or automatic 50% duty cycle (PW=0) Min-Max Flow Alarm: Open collector or solid state relay (programmable – 0 to 100% of ﬂ ow)

Empty Pipe Detection: Field tunable for optimum performance based on speciﬁ c application Excitation Frequency: Programmable - 3.75Hz, 7.5Hz or 15Hz (3.125, 6.25, 12.5) Auxiliary Input: Max. 24VDC (programmable – positive zero return, external totalizer reset or preset batch start)

Noise Dampening: 1 to 30 seconds (programmable) Units of Measure: U.S. gallons, imperial gallons, million

gallons per day, cubic feet, cubic meters, liters, oil barrels, pounds, ounces, acre feet

Low Flow Cut-Off: 0 to 100% of full scale (programmable) Zero-Point Stability: Automatic correction LC Display: 4 lines X 16 character alphanumeric – back

light, actively displays 3 totalizer values, ﬂ ow rate, alarm status, output status, error / diagnostic messages

Programming: Internal 3 button or external magnetic wand Galvanic Separation: 500 volts Electrical Classiﬁ cation:

FM approved for Class I, Div 2, Groups A-D Class II, Div 2, Groups F and G - CSA Certiﬁ ed Housing: Ampliﬁ er enclosure and remote junction enclosure: cast aluminum (powder coated paint) Housing Rating: Ampliﬁ er enclosure and remote junction enclosure – NEMA 4X/6P (IP66/IP67) Mounting: Direct detector mount or remote wall mount – bracket included. (for remote mount, max. cable distance = 100 ft (30M)

Field Wiring Entry Ports: (3) ½" NPT, internal thread Ambient Temperature: -4°F to 122°F (-20°C to 50°C) Relative Humidity: Up to 90% non-condensing Locations: Indoor and outdoor Altitude: Maximum 6500 feet (2000m)

MAINTENANCE

Mandatory, routine or scheduled maintenance should not be required for the Badger ﬂ ow tube after proper installation.

M-3000 Mag Meter electronics or

Detector coil and incoming ampliﬁ er power supplies are each protected by a fuse in the ampliﬁ er.

Detector coils are protected by a 630mA, 250VAC, slow blow fuse, part number 65621-001.

However, some occurrences may require personnel to perform the following:

· Flow Tube and Electrode Cleaning

· Fuse Replacement

· Ampliﬁ er I&C Card Stack Replacement

These maintenance procedures are discussed in this section.

Disconnect main power to the unit before attempting any device maintenance or cleaning. Do not clean components inside the ampliﬁ er or junction box.

Flow Tube and Electrode Cleaning

At times ﬂ ow tube, electrodes, ampliﬁ er/junction box housings and the ampliﬁ er window may need periodic cleaning, depending on process ﬂ uid properties, ﬂ uid ﬂ ow rate and surrounding environment.

Clean the ﬂ ow tube and electrodes by following the material handling and cleaning procedures documented in MSD Sheets for the products(s) that were in contact with the ﬂ ow tube and electrodes.

For the AC powered version, the incoming ampliﬁ er power is protected by a 500mA, 250VAC, slow blow fuse, part number 65621-002.

For the 24VDC powered version, the incoming ampiﬁ er power is protected by a 630mA 250VAC, slow blow fuse, part number 65621-001.

Fuse ratings are listed on the circuit board, next to the fuse holders. Refer to the M-Series™, Model M-3000 Repair Parts List (IRP-210-01).

To access and replace fuses:

1. Remove display chamber cover. Turn the cover counterclockwise to remove it from the ampliﬁ er. If necessary, use a strap wrench.

Should ﬂ ow tube and/or electrode cleaning become necessary:

1. Disconnect detector from pipeline.

2. Clean electrodes with isopropyl alcohol or fresh, clean water depending on the chemical compatibility of the measured ﬂ uid.

3. Reconnect detector to pipeline

Fuse Replacement

Disconnect main power to the unit before attempting any device maintenance.

Risk of electrical shock. Replace fuse ONLY with the same type and rating.

Authorized personnel must perform fuse replacements.

Replace fuses with fuses of the same ampere rating and type. Refer to wiring diagrams when ampere ratings are unknown or questionable.

2. Remove the 2 display card screws and washers.

3. Tilt card up/out approximately 45 degrees at the holding clips.

4. Fuses are in the round/black fuse holders. Use a ﬂ at screwdriver to turn the holder cap counterclockwise until the lock tab reaches the opening and the holder and fuse disengage.

5. Replace the fuse.

REMOVE PCB STACK

Disconnect main power to the unit before attempting any device maintenance.

1. Remove display/programming chamber cover. Turn the cover counterclockwise to remove it from the ampliﬁ er. If necessary, use a strap wrench.

2. Remove 2 display card screws and washers. Place in storage for reuse.

6. Reverse steps 1 to 3 to assemble the unit.

Ampliﬁ er Printed Circuit Board (PCB) Stack Replacement

All M-3000 mag meters operate through printed circuit boards (PCBs) housed in the ampliﬁ er. The PCBs are grouped in a stack located behind the display/control card in the display/programming chamber.

Because PCBs are complex circuits, with all meter functions enabled through multiple links and layers, determining the exact board and circuit that is causing a system problem is difﬁ cult and usually requires test equipment.

Should a meter problem occur:

1. Call Badger Meter at (877) 243-1010, and discuss the problem with a Technical Support Specialist.

2. If the problem appears to originate in a PCB, it will be recommended that the entire PCB stack be removed and returned to Badger Meter.

PCB Stack

3. Tilt display card up/out approximately 45 degrees at the holding clips.

4. Gently pull card down and out from between holding clips.

5. Disconnect display card plug from left side of PCB display.

PCB Stack in Ampliﬁ er

6. Disconnect the Power, Coil, Electrode and I-O plugs and harnesses from the PCB interconnect card.

9. Carefully wrap and package the PCB stack and display card. Send back to Badger Meter.

10. Reverse these steps to install a PCB stack.

When replacing the PCB stack: a.) Be sure to place the two lower feet of the circuit

board support along the edges of the ampliﬁ er housing.

b.) Gently move the stack back into the housing until

the to holes at the top mate with the housing. (The stack is not connected to the circuit board in this picture.)

7. Remove the 4 screws holding the PCB stack in the ampliﬁ er housing. Place in storage for reuse.

8. Gently remove the card stack from the ampliﬁ er housing. Do not tug or pull to remove the stack. Ease it out carefully.

11. When placing display card back into PCB Display, verify mark and red stripe are aligned with Number 1.

FLOW CHART - MENU STRUCTURE

Menu Structure

Meter Setup

Pipe Dia.

Enter the flow tube diameter

Detect Factor

Enter the meter calibration factor

Excitation Freq

Select the coil excitation frequency

Calibration

Electric Zero

All calibration factors

Elec Full Scale

are determined at the

Hydr. Zero-Man

factory.

Hydr. Zero-Auto

Empty Pipe Cal. empty pipe

Empty pipe detection setup.

Cal. full pipe Enable/Disable

Chg. Password

Password new

Enter 0000 to disable password.

Measurements

Rate Unit Select flow rate unit Totalizer Unit

Select total volume unit

FullScaleFlow Enter full scale flow for the analog output. LowFlowCutOff

Enter the low flow cut off. Typically 0.2%

Flow Dir. Select uni-directional or bi-directional flow. Damping Factor Select as needed.

In the Flow Chart:

1. Each separate screen is inside a box.

2. If a screen “branches”, an arrow points right and each screen of the branch is in a box.

3. When there is text, but it’s not in a box, that signiﬁ es a parameter setting and a short explanation is given of the parameter.

Mark on the chart what parameters need to be set. Note parameter settings on the chart. Program your ampliﬁ er accordingly.

Keep the chart as a reference for other shifts and personnel and to monitor meter performance.

Digital Input 1 Select function for input.

Digital Out. #1 Open collector Pulse width Transistor Set point min.

Digital Out. #2 Open collector Pulse width Set for Reverse pulse output. Transistor Full Scale Freq Set for Frequency output. Full scale = ? Hz

Pulses / unit

Set point max. Output Type

Select Function

Pulses / unit Set for Reverse pulse output.

Preset Amount Set batch amount for Preset Output. Set point min. Set point max. Output Type

Select Function

Set for Forward pulse output Set for Forward pulse output Set for Flow Set Point output Set for Flow Set Point output Select N.O. or N.C. for any output function.

None Fwd Pulse / AMR

MR Flow Set Point Error Alarm EmptyPipe Error Flow Direction

Set for Flow Set Point output Set for Flow Set Point output Select N.O. or N.C. for any output function.

None Reverse Pulse

Freq. Output Preset Output Flow Set Point Error Alarm EmptyPipe Error Flow Direction

Forward flow pulse output. Forward flow pulse for AMR devices. Output will open or close based on set points. Output will open or close during error conditions. Output will open or close when the pipe is empty. Output will open or close when flow direction changes.

Reverse flow pulse output. Frequency out is proportional to rate of flow. Output will open or close when preset amount is reached. Output will open or close based on set points. Output will open or close during error conditions. Output will open or close when the pipe is empty. Output will open or close when flow direction changes.

Digital Out. #3 Preset Amount Set batch amount for Preset Output. Solid state relay Set point min.

Set point max. Output Type

Select Function

Set for Flow Set Point output Set for Flow Set Point output Select N.O. or N.C. for any output function.

None Preset Output

Flow Set Point Error Alarm EmptyPipe Error Flow Direction

Output will open or close when preset amount is reached. Output will open or close based on set points. Output will open or close during error conditions. Output will open or close when the pipe is empty. Output will open or close when flow direction changes.

Clear Totals

Digital Out.#4

Solid state relay Set point min.

Sets totals to Zero.

Preset Amount Set batch amount for Preset Output.

Set point max. Output Type

Select Function

Set for Flow Set Point output Set for Flow Set Point output Select N.O. or N.C. for any output function.

None Preset Output

Flow Set Point Error Alarm EmptyPipe Error Flow Direction

Communications

Info/Help

Logout Version No

Language Select

Serial Port Select Baud RS232 communications setup.

Select Parity No. Data Bits Select StopBits Sel. Interface

Error Counts PowerUp Counter

Support Phone#

Restore Defs.

Please call Badger Meter's Technical Support department at 800-456-5023 for questions related to programming and set-up.

M-Series™ is a trademark of Badger Meter, Inc.

is a registered trademark of Badger Meter, Inc.

Badger

is a registered trademark of Ausimont U.S.A., Inc.

Halar

Please see our website at

www.badgermeter.com

for speciﬁ c contacts.

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

BadgerMeter, Inc.

P.O. Box 245036, Milwaukee, WI 53224-9536 Telephone: (414) 355-0400 / (800) 456-5023 Fax: (414) 355-7499 / (866) 613-9305 www.badgermeter.com

Badger Meter M3000 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual