Badger Meter M4000 User Manual

M-Series® Mag Meter
Model M-4000
Installation &
Operation Manual
IMPORTANT !!!! Read this manual before
attempting any handling or installation of the meter.
IOM-123-03
BadgerMeter, Inc.
53400-123 Rev. 3
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: (414) 355-7499, (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-4000______ Serial Number _____________ Tag Number _______________(if applicable)
2
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
External Disconnect ..................................................................................................................................................................... 15
AC Power Wiring ........................................................................................................................................................................... 15
Adjustable Display/Control Card ................................................................................................................................................... 15
AMPLIFIER CONTROLS, CONTROL METHODS AND DATA DISPLAY PROGRAMMING ......................................................16
Card Display and Controls ............................................................................................................................................................ 16
Two Programming Methods .......................................................................................................................................................... 17
Main Screen(s) ............................................................................................................................................................................. 17
Password ...................................................................................................................................................................................... 18
Amplifi er Access Switches/Buttons .............................................................................................................................................. 18
How to Program ............................................................................................................................................................................ 19
What to Program ..........................................................................................................................................................................22
PROGRAMMING REQUIRED PARAMETERS ............................................................................................................................ 22
Input a Password ..............................................................................................................
Set Flow Units ..............................................................................................................................................................................23
Set Full Scale Flow ....................................................................................................................................................................... 23
Set Low Flow Cutoff .....................................................................................................................................................................23
Set Flow Direction ........................................................................................................................................................................24
Set Damping Factor ...................................................................................................................................................................... 24
Empty Pipe Calibration ................................................................................................................................................................. 24
Pulse Output ................................................................................................................................................................................. 25
Analog Output ............................................................................................................................................................................... 27
DETECTOR SPECIFICATIONS ................................................................................................................................................... 29
AMPLIFIER SPECIFICATIONS ................................................................................................................................................... 30
MAINTENANCE ........................................................................................................................................................................... 31
Flow Tube and Electrode Cleaning ............................................................................................................................................... 31
Fuse Replacement .......................................................................................................................................................................31
Amplifi er PCB Stack Replacement ...............................................................................................................................................32
FLOW CHART - MENU STRUCTURE ......................................................................................................................................... 34
............................................................ 22
3
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.
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.
7. All detectors with PTFE liners are shipped with a liner protector to maintain proper form of the PTFE material during shipping and storage.
NOTE: Do not remove the liner protector until installation.
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.
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.
4
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.
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.
Additional Information
Certifi cation markings are noted on the product label. Markings include:
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.
Instructions Specifi c to Hazardous Area Installations
These instructions apply to equipment covered by FM Certifi cate Number 3015930.
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)
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-4000 electromagnetic meters are FM approved for Class I, Div 1 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-4000 Mag 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
5
the electrode is again covered with fl uid, the error message disappears and the meter continues measuring.
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 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.
METER/AMPLIFIER LOCATION, ORIENTATION and APPLICATIONS Remote Amplifi er Outdoor Location
The amplifi er can be installed and operated outdoors. However, protection from the elements must be considered:
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.
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 and PTFE.
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 and PTFE.
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.
5. The ambient temperature range surrounding the amplifi er is -4°F to 122°F (-20°C to 50°C.)
6
6. The ambient temperature range surrounding a remote
Electrode
Plane
RIGHT
Electrode
Plane
WRONG
FORWARD FLOW
MINIMUM STRAIGHT PIPE
MINIMUM STRAIGHT PIPE
ELBOW
TEE
GATE VALVE
(FULLY OPEN)
MINIMUM STRAIGHT PIPE
CHECK VALVE GLOBE VALVE
BUTTERFLY VALVE
PUMP
ELBOW TEE ANY VALVE
M-4000 Mag FLOWMETER
3 x D
7 x D
2 x D
D (Pipe Size)D (Pipe Size)
MINIMUM PIPING REQUIREMENT
STANDARD CONCENTRIC REDUCERS
(NO DISTANCE REQUIRED)
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.
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.
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.
This arrangement prevents solids build-up or sediment deposit or accumulation on the electrodes.
Straight Pipe Requirements
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.
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.
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.
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).
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
7
the meter and the injection point must be signifi cant; 50 to
WRONG
FLOWFLOW
FLOW
FLOW
FLOW
FLOWFLOW
WRONG
FLOW
FLOW
FLOWFLOW
RIGHT
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: 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.
ALWAYS locate ON/OFF valves on the
downstream side of the meter
To eliminate these situations:
Do not install the meter in
the highest point of the pipeline
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
Meter Gaskets and Grounding
Two other considerations to meter location, orientation and application are gasket and grounding requirements and placement.
Meter/Pipeline Connection Gaskets
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.
Do not install the meter in a vertical,
downward fl ow section of pipe
If a grounding ring is used in the detector/pipeline connection, place the ring between two gaskets. (See Non-
Conductive Pipe Grounding section.)
Meter Grounding
Process pipeline material can be either electrically conductive (metal) or not electrically conductive (made of or lined with PVC, fi berglass or concrete).
8
METER INSTALLATION PLANS and EXECUTION
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
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 and moving 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.
GASKETS RECOMMENDED
After the grounding rings, gaskets and meter are assembled to the pipeline, attach ground straps (provided) of copper wire, at least 12AWG size, to grounding bolts on meter fl anges and to the grounding rings.
If your meter was ordered with an optional grounding electrode, the use of grounding rings is not necessary.
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.
9
Mount Bracket/Amplifi er to Location
1. Position the bracket/amplifi er in the desired orientation.
2. Secure bracket/amplifi er to location.
REMOTE MOUNT AMPLIFIER/DETECTOR WIRING
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.
· 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 Remote Mount Amplifi er Junction 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 1 hazardous locations.
Failure to use proper conduit fi ttings rated for Class I, Div 1 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 4X, 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.
10
G
LN
6
12345
3
12456
OR
L-BROWN
1
2
WHITE
E1
N-BLUE
345
SHLD
WHITE
PINK
BLACK
GREEN
SHLD
SHLD
+5V
+5V
-5V
-5V
EP
EP
E2
E2
SHLD
SHLD
E1
E1
RED
GREEN
BLACK
WHITE
SHIELD
C1 C2 SHLD
SHIELD
RED
CLEAR
SHIELD
RED
CLEAR
BELDEN 8770
OR
EQUIVALENT
6
GREEN
PINK
BLACK
EP
E2
-5V
+5V
SHLD
SHIELD
CLEAR
RED
18" MAX
BETWEEN HOUSING
AND CONDUIT SEAL
SEAL
BELDEN 9155 OR EQUIVALENT
FOR CLASS 1 DIV 1
OR CLASS 1 DIV 2
FOLLOW NEC 504
BELDEN 9155 OR EQUIVALENT
18 AWG
WHITE
SHIELD
2
18/20 AWG OR 1.0 / 0.5 mm
20 AWG
18 AWG
20 AWG
RED
BLACK
GREEN
2
18 AWG OR 1mm
RED
CLEAR
SHIELD
SEAL
BELDEN 8770
OR
EQUIVALENT
18" MAX
BETWEEN HOUSING
SHLD C2 C1
E1
SHLD
E2
EP
-5V
+5V
SHLD
AND CONDUIT SEAL
L
L-BROWN
E1
SHLD
E2
EP
-5V
+5V
SHLD
C1
C2
SHLD
N
N-BLUE
G
NOTE: RUN WIRES ALONG
THE BOTTOM OF
THE HOUSING.
FOR CLASS 1 DIV 1 OR 2
FOLLOW NEC 501.4
AND 501.5
PLUG IN HERE
INTERMEDIATE METAL CONDUIT
OR RIGID METAL CONDUIT
NOTE:
THE TOTAL RESISTANCE OF THE GROUND CONNECTION
FROM THE DETECTOR TO THE AMPLIFIER CAN
NOT EXCEED 1 OHM (TERMINAL 44)
ADD JUMPER TO CONNECT
SHIELDED TERMINALS
REMOTE MOUNT WIRING DIAGRAM
CLASS 1 DIV 1, ZONE 1
BLUE SLEEVE(FROM COIL)
RED SLEEVE(FROM COIL)
GROUND POST
BACK ELECTRODE
BLACK SLEEVE
WHITE SLEEVE
E1
E2
SHLD
SHIELDS
PINK SLEEVE
GREEN/YELLOW
EP
-5V
+5V
SHLD
CUSTOMER PROVIDED PROTECTING
EARTH GROUND CONNECTION
NEC 505.25
COIL
COIL
FRONT ELECTRODE
DOWNSTREAM FLANGE
11
NOTE: Plastic cover must be reattached to maintain
RED
SHIELD
CLEAR
SHIELD
18 AWG
OR 1mm
2
BELDEN 9155 OR EQUIVALENT
BELDEN 8770 OR EQUIVALENT
18/20 AWG
OR 1.0 / 0.5 mm
2
20 AWG
18 AWG
20 AWG
18 AWG
FOR ZONE 1 INSTALLATION
CONDUIT SEAL LOCATED AT ENCLOSURE ENTRY PER 505.18
SEAL
FOR CLASS 1 DIV 1 OR 2 FOLLOW NEC 501.4 AND 501.5. FOR CLASS 1 ZONE 1 FOLLOW NEC. 505.15 AND 505.18
EP
E2
SHLD
SHLD
E1
SHLD C2 C1
+5V
-5V
EP
E2
SHLD
SHLD
E1
WHITE BLACK
GREEN
RED
+5V
-5V
ELECTRODE WIRES
SHIELD
RED GREEN BLACK WHITE
BELDEN 9155 OR EQUIVALENT
SHIELD
BELDEN 8770 OR EQUIVALENT
RED CLEAR
SEAL
SHIELD
RED
CLEAR
FOLLOW NEC 504
BLACK
WHITE
GREEN
PINK
C1 C2 SHLD
E1
SHLD
+5V
E1
SHLD
E2
EP
SHLD
-5V
+5V
-5V
EP
E2
SHLD
CONDUIT SEAL LOCATED AT ENCLOSURE ENTRY PER 505.18
FOR ZONE 1 INSTALLATIONS
ELECTRODE WIRES
RED
SHIELD
CLEAR
SHIELD
18 AWG
OR 1mm
2
BELDEN 9155 OR EQUIVALENT
BELDEN 8770 OR EQUIVALENT
18/20 AWG
OR 1.0 / 0.5 mm
2
20 AWG
18 AWG
20 AWG
18 AWG
FOR ZONE 1 INSTALLATION
CONDUIT SEAL LOCATED AT ENCLOSURE ENTRY PER 505.18
SEAL
FOR CLASS 1 DIV 1 OR 2 FOLLOW NEC 501.4 AND 501.5. FOR CLASS 1 ZONE 1 FOLLOW NEC. 505.15 AND 505.18
EP
E2
SHLD
SHLD
E1
SHLD C2 C1
+5V
-5V
EP
E2
SHLD
SHLD
E1
WHITE BLACK GREEN
RED
+5V
-5V
COIL WIRES
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
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.
Cable length, between Junction Boxes, may be up to 100 feet (30M).
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.
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.
Red to terminal labeled – C1 Clear to terminal labeled – C2
5. Connect conduit to junction box. Use a NEMA 4X 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).
12
Coil Wiring in Amplifi er Junction Box
SHIELD
RED GREEN BLACK WHITE
BELDEN 9155 OR EQUIVALENT
SHIELD
BELDEN 8770 OR EQUIVALENT
RED CLEAR
SEAL
SHIELD
RED
CLEAR
FOLLOW NEC 504
BLACK
WHITE
GREEN
PINK
C1 C2 SHLD
E1
SHLD
+5V
E1
SHLD
E2
EP
SHLD
-5V
+5V
-5V
EP
E2
SHLD
CONDUIT SEAL LOCATED AT ENCLOSURE ENTRY PER 505.18
FOR ZONE 1 INSTALLATIONS
COIL WIRES
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.
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).
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.
Red to terminal labeled – C1 Clear to terminal labeled – C2
4. Connect conduit to junction box. Use a NEMA 4X ½ inch NPT fi tting.
5. Install protective plastic cover over terminal blocks.
6. Attach the amplifi er junction box chamber cover.
OUTPUT WIRING
The Badger
®
M-4000 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 1 hazardous locations.
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.
13
Functions: Forward (only) Pulse AMR Pulse Flow Set Point Error Alarm Empty Pipe Flow Direction
Output 1 (+) 3
Common 4
02
01
+
External Counter Badger Meter ER8 or AMR Device
}
Programmable
• Output 1 Transistor Output (open collector) 24VDC Max .5W Max
Passive Output Wiring
_____________________________________________
• 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
02
01
+
External Counter Badger Meter ER8 or AMR Device
External Disconnect
Terminal 1 Input 1 (+) - Input -
Functions: reset, positive zero return.
Terminal 2 Output 1 (+) Programmable passive output to
®
Badger
external counter. Functions: forward pulse, frequency output, preset output, fl ow set point, error alarm, fl ow direction Active Output to external counter.
Terminal 3 Output 1 (+) ProgrammableTransistor Output (open collector) - 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 Common fi eld ground.
Terminal 5 Analog Output.
Terminal 6 Ground from external counter device connected
to terminal 5.
Auxiliary Input Wiring Diagram
Function: Reset Positive Zero Return
Input 1 (+) 1
5-24VDC
Common 4
_____________________________________________
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 Power Wiring
For AC power use three wire, sheathed, cable with cable diameter of 18 AWG (not supplied).
AC wire insulation temperature class must not exceed the maximum ambient temperature of its location (typical, 185°F, 85°C).
Use conduit and conduit fi ttings (not supplied) that are rated for Class I, Div 1 hazardous locations. To maintain a NEMA 4X rating, use watertight fi ttings that are rated NEMA 4X or better.
To prevent accidents connect main power only after all other wiring has been completed.
Analog Output Wiring Diagrams
• Analog Output (Loop voltage = 18VDC Sourced, 750 MAX)
mA Analog Output (+) 5
Common 6
_____________________________________________
Function: 4-20mA 0-20mA 0-10mA
14
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.
AC wiring is the same for meter mount and remote mount amplifi ers.
1. Remove AC Wires Port screw from amplifi er connections chamber.
2. Lay out AC cable and conduit to amplifi er.
3. Place cable in conduit.
4. Strip AC cable back 2 inches (50mm).
5. Strip AC wires back ¼ inch (6mm).
6. Attach AC wires to amplifi er terminal.
Black to L White to N Green to G
L
85-265 VAC
N
G
45-65 Hz
Amplifier AC wires
and
terminal
7. Connect conduit to amplifi er.
8. Attach chamber cover.
3. Tilt card up/out approximately 45 degrees at the holding clips.
4. Gently pull card down and out from between holding clips.
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.
To re-position or rotate the display/control card in the amplifi er:
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.)
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.
15
8. Attach the chamber cover.
ACCESS to AMPIFIER SCREENS, DATA and PARAMETER PROGRAMMING NOTE: The M-4000 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-4000 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.
AMPLIFIER CONTROLS, CONTROL METHODS and DATA DISPLAY PROGRAMMING
The M-4000 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-4000 uses a 2.5 X 1 inch (63 X 25mm) four line, 16-character, backlit, LCD display.
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.
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.
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.
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.
16
Tw o Main Screen Format settings are possible. Which setting to use is determined by the fl uid Flow Direction th
rough your meter. The settings are Uni-Directional fl ow or Bi-Directional fl ow (reference page 23, "Set Flow Rate - Unit of Measure and Totalizer Unit of Measure" to program fl ow units).
Both main screens display the rate of fl ow (R=) and fl ow units.
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.
Uni-Directional Flow Main Screen
Uni-directional Flow Totalizes Pipe Flow in only one direction, the fl ow direction arrow printed on the detector label. (refere
nce page 24, "Set Flow Direction" to program for uni-
directional fl ow)
Uni-directional readings, on the display main 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
1.
PS registers Preset Batch Amount
PASSWORD??? 01 is a typical Input Numbers screen.
If a password has been entered into your program, this screen opens (reference page 22 "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.
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.
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 (refere
nce page 24, "Set Flow Direction" to program for Bi-
Directional Flow)
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
TN Net Total = (T+) - (T-) PS registers Present Batch Amount
However, if the wrong password was entered: Screen INVALID PSWD 02 opens.
1. Select +, - or E to return to the Main Screen.
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.
17
Switch/Buttons (+ and -)
MAIN MENU 00
---------------­>Exit this Menu Meter Setup Measurements Inputs/Outputs Clear Totals Communications Info/Help Logout
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
· Continue selecting E to return to the Main Screen.
· 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.
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
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
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”.
Sample Input Numbers Screen
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.
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.
18
MAIN MENU 00
---------------­>Exit this Menu Meter Setup Measurements Inputs/Outputs Clear Totals Communications Info/Help Logout
Only four lines of text are visible on the display screen.
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"]
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.
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.
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.
PIPE DIA. 11 is a list of pipe diameter sizes.
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.
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.
4. Screen METER SETUP 10 opens.
5. Press + or – to position the arrow at the appropriate pipe size.
19
6. Press E.
4. 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.
Transitions
1. Press + or to position the arrow at another selection or E to return to the Main Menu.
5. Press + three times to position arrow at Digital Out. #1 on screen In/Outputs 30.
6. Press E.
7. Press + once to move the arrow across from Pulses / unit.
8. Press or activate E.
2. Use the E key to return to screen Main Menu 00.
3. Next, press + three times to position arrow at Inputs/ Outputs.
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
20
programmed into the system and the screen Dig Output 1
33 returns.
Screen.
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.
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.
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.
Input a Password
1. With Main Screen up, press E, to open MAIN MENU 00.
5. Select or press E.
6. Screen Empty Pipe 15 opens.
Empty Pipe 15 is a typical select ON/OFF screen.
Empty Pipe is usually 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].
2. With MAIN MENU 00 up, press + once to move cursor to Meter Setup. Press E.
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. 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
5. Or this screen comes up. Input the correct password.
6. If the wrong number is input, INVALID PSWD comes up.
21
Press +, - or E once.
7. Main Screen appears. Press E again.
8. PASSWORD??? 01 screen reactivates. Input the correct password.
Set Flow Rate - Unit of Measure and Totalizer Unit of
Measure
1. With Main Screen up, press E.
6. The screen returns to MEASUREMENTS 20. With the cursor at Exit this Menu, press + twice to move cursor to Totalizer Unit. Press E.
7. From TotalizerUnit 22 press + or - to select a totalizer unit. Press E.
8. This type of screen shows for two seconds.
9. Screen goes back to MEASUREMENTS 20.
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.
4. From FLOW UNITS 21 press + or - to select a fl ow unit. Press E.
Set Full Scale Flow Rate Value
1. Press + three times to move the cursor to FullScaleFlow. Press E.
2. At FullScaleFlow 23 input the proper fl ow. Select E to move cursor as described earlier.
3. Screen returns to MEASUREMENTS 20.
SET LOW FLOW CUTOFF
1. Press + four times, to place cursor at LowFlowCutOff. Press E.
5. This type of screen shows for two seconds.
22
2. At LowFlowCutOff 24 screen input a percentage at the arrow. Press E.
4. And this type of screen shows for 2 seconds when Damping Factor time is selected.
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 to Meter Setup.
3. In METER SETUP 10, select Empty Pipe.
23
4. In EMPTY PIPE 15, select Cal. empty pipe.
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.)
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.
10. In EMPTY PIPE 15, press + three times to place cursor at Enable/Disable. Next, press E.
11. In EMPTY CONTROL 1G, press + twice to move cursor to Det[OFF] E=ON. Press E once to switch OFF to ON.
12. Press + once to move cursor to Exit WITH save. Press E once to save the setting and return to EMPTY PIPE 15.
7. In EMPTY PIPE 15, select at Cal. full pipe. Then, press E.
8. Select Cal[OFF] E=ON, press or select E once to change to OFF to ON. is full of fl uid.)
NOTE: The full pipe voltage reading should be below
3.00 Volts.
9. Press + once to move cursor to Exit WITH save. Press E once to save the setting and return to EMPTY PIPE 15.
(NOTE: Make sure the Flow Detector pipe
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.
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.
24
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 35, "Digital Output #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.
will activate.
2. The Screen returns to DIG OUTPUT 1 33. Press + four times, then press E.
3. In SET PT. MAX 3G enter a number as described earlier.
NOTE: When the fl ow rate exceeds the set point value (entered as a percentage of full scale), the output will activate.
This is only for Flow Set Point. (Refer to page 35 "Digital Output #1.)
This is only for Fwd Pulse. (Refer to page 35, "Digital Output #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 35, "Digital Output #1.")
1. Into screen SET PT. MIN 3F enter a number as described earlier. Press E.
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 35, "Digital Output #1.
NOTE: When the fl ow rate falls below the minimum setpoint
valvue (entered as a percentage of full scale), the output
• Normally Opened or Closed **Selected** shows for two seconds.
25
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.)
• 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.
Analog Output
1. Press E once to move cursor to Main Menu.
2. In the MAIN MENU 00, press + three times to move the cursor to Inputs/Outputs. Next, press E.
3. At IN/OUTPUTS 30 press + once to place the cursor at Analog Output. Press E.
7. This type of screen shows for two seconds and then returns to DIG OUTPUT 1 33.
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 select Out #1 35 are
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.
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 5 and 6.
7. In ANALOG ZERO 3B make a selection of Decrease or
Increase based on what the amp meter is reading.
26
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.)
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.
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 functions that need to be programmed initially. Please refer to the programming fl ow chart located on pages 34-36 for all of the programming options.
13. Press + to set screen at Exit WITH save.
14. Press E to Save.
27
DETECTOR SPECIFICATIONS
SIZE
7.52" 191mm
5.20" 132mm
7.22" 183mm
B
A
ØC
3.54" 90mm
4.25" 108mm
9.20" 234mm
5.47" 139mm
3.73" 95mm
SIZE
M-4000 Meter Mount Amplifi er on Detector M-4000 Remote Mount Junction Box on Detector
9.20"
7.52" 191mm
5.20" 132mm
8.35" 212mm
7.64"
7.42" 194mm
188mm
B
A
234mm
5.47"
3.73"
139mm
95mm
7.22" 183mm
14.52 368mm
ØC
SIZE
Est. Weight
Flow Range
Size A B C D with Amplifi er GPM LPM
inch mm inch mm inch mm inch mm inch mm Lbs Kg Min Max Min Max
¼ 6 6.7 170 14.45 366 3.5 89 15.15 388 12.5 5.7 0.02 5 0.063 20
5
/16 8 6.7 170 14.45 366 3.5 89 15.15 388 12.5 5.7 0.03 9 0.114 34
3
/8 10 6.7 170 14.45 366 3.5 89 15.15 388 12.5 5.7 0.05 14 0.177 53 ½ 15 6.7 170 14.45 366 3.5 89 15.15 388 12.5 5.7 0.11 33 0.416 125 ¾ 20 6.7 170 14.65 371 3.9 99 15.25 393 15.5 7.0 0.2 59 0.75 225 1 25 8.9 225 14.85 376 4.3 108 15.45 398 22.0 10.0 0.3 93 1.20 350 1¼ 32 8.9 225 15.65 396 4.6 117 16.25 418 24.0 10.9 0.5 152 2.00 575 1½ 40 8.9 225 15.85 400 5.0 127 16.45 422 25.0 11.4 0.8 239 3.00 900 2 50 8.9 225 16.35 413 6.0 152 16.95 435 29.5 13.4 1 373 4.70 1400 2½ 65 11.0 280 17.55 444 7.0 178 18.15 466 42.0 19.0 2 631 8 2400 3 80 11.0 280 17.85 450 7.5 191 18.45 472 43.6 19.8 3 956 12 3600 4 100 11.0 280 18.85 476 9.0 229 19.45 498 54.1 24.6 5 1493 19 5600 5 125 15.8 400 20.05 508 10.0 254 20.65 530 80.0 36.4 8 2334 30 8800 6 150 15.8 400 21.05 534 11.0 279 21.65 556 83.2 37.8 11 3361 40 12700 8 200 15.8 400 22.95 582 13.5 343 24.15 618 127.6 58.0 20 5975 75 22600 10 250 19.7 500 27.25 691 16.0 406 27.85 713 162.4 73.8 30 9336 120 35300 12 300 19.7 500 29.35 744 19.0 483 29.95 766 250 113.6 45 13444 170 50800
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 12" (6 to 300mm) 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 12" (15 to 300mm), soft and hard rubber from 1" to 12" (25 to 300mm)
NSF Listed:
Models with hard rubberl liner, 4-inch and up PTFE liner - all sizes
Fluid Temperature:
With remote mounted amplifi er PFA, PTFE: -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: -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)
Pressure Limits: Max. 150 psi (10 bar) Ambient Temperature: -20°F to 122°F (-29°C to 50°C) Coil Power: Pulsed DC Pipe Spool Material: 316 stainless steel Spool Housing Material: Carbon steel, welded - NEMA 4 (IP66) Junction Enclosure Material: (for remote mounted amplifi er option)
Cast aluminum (powder coated paint), NEMA 4X (IP66)
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 12" (250 to 300mm) .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 1 Groups C-D, Class II, Div 1 Groups E, F & G - CSA Certifi ed
Pressure Limits: Max. 150 psi (10 bar) Ambient Temperature: -4ºF to 122ºF (320ºC to 50ºC) Locations: Indoor and outdoor Altitude: Maximum 6500 feet (2000m)
28
AMPLIFIER SPECIFICATIONS
SPECIFICATIONS
Power Supply: 85-265VAC, 45-65Hz Power Consumption: 20W 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 Pulse Width: Open collector, 5ms to 1 second (programmable) or automatic 50% duty cycle 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
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 I, Groups B-D Class II, Div 2, Groups E, 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 (IP66) 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: -20°F to 122°F (-29°C to 50°C) Communication: RS232C serial, standard ANSI terminal
compatible data stream
29
MAINTENANCE
Mandatory, routine or scheduled maintenance should not be required for the Badger fl ow tube after proper installation.
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.
®
M-4000 Mag Meter electronics or
Detector coils are protected by a 630mA, 250VAC, slow blow fuse, part number 65621-001.
Incoming amplifi er power is protected by a 500mA, 250VAC, slow blow fuse, part number 65621-002.
Fuse ratings are listed on the circuit board, next to the fuse holders. Refer to the M-Series™, Model M-4000 Repair Parts List (IRP-211-01).
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.
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.
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.
2. Remove the 2 display card screws and washers.
3. Tilt card up/out approximately 45 degrees at the holding clips.
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.
Detector coil and incoming amplifi er power supplies are each protected by a fuse in the amplifi er.
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.
30
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-4000 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.
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.
31
7. Remove the 4 screws holding the PCB stack in the amplifi er housing. Place in storage for reuse.
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.)
11. When placing display card back into PCB Display, verify mark and red stripe are aligned with Number 1.
8. Gently remove the card stack from the amplifi er housing. Do not tug or pull to remove the stack. Ease it out carefully.
32
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.
33
Digital Input 1 Select function for input.
Digital Out. #1
Pulses / unit
Set for Forward pulse output.
Open collector Pulse width
Set for Forward pulse output.
Transistor Set point min.
Set for Flow Set Point output.
Set point max.
Set for Flow Set Point output.
Output Type
Select N.O. or N.C. for any output function.
Select Function
None Fwd Pulse / AMR
Forward flow pulse output.
A
MR
Forward flow pulse for AMR devices.
Flow Set Point
Output will open or close based on set points.
Error Alarm
Output will open or close during error conditions.
EmptyPipe Error
Output will open or close when the pipe is empty.
Flow Direction
Output will open or close when flow direction changes.
Digital Out. #2
Pulses / unit Set for Reverse pulse output. Open collector Pulse width Set for Reverse pulse output. Transistor Full Scale Freq Set for Frequency output. Full scale = ? Hz
Preset Amount Set batch amount for Preset Output.
Set point min.
Set for Flow Set Point output
Set point max.
Set for Flow Set Point output
Output Type
Select N.O. or N.C. for any output function.
Select Function
None Reverse Pulse
Reverse flow pulse output.
Freq. Output
Frequency out is proportional to rate of flow.
Preset Output
Output will open or close when preset amount is reached.
Flow Set Point
Output will open or close based on set points.
Error Alarm
Output will open or close during error conditions.
EmptyPipe Error
Output will open or close when the pipe is empty.
Flow Direction
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 for Flow Set Point output
Set point max.
Set for Flow Set Point output
Output Type
Select N.O. or N.C. for any output function.
Select Function
None Preset Output
Output will open or close when preset amount is reached.
Flow Set Point
Output will open or close based on set points.
Error Alarm
Output will open or close during error conditions.
EmptyPipe Error
Output will open or close when the pipe is empty.
Flow Direction
Output will open or close when flow direction changes.
34
Digital Out.#4
Preset Amount Set batch amount for Preset Output.
Solid state relay Set point min.
Set for Flow Set Point output.
Set point max.
Set for Flow Set Point output.
Output Type
Select N.O. or N.C. for any output function.
Select Function
None Preset Output
Output will open or close when preset amount is reached.
Flow Set Point
Output will open or close based on set points.
Error Alarm
Output will open or close during error conditions.
Clear Totals
Sets totals to Zero.
EmptyPipe Error
Output will open or close when the pipe is empty.
Flow Direction
Output will open or close when flow direction changes.
Communications
Serial Port Select Baud RS232 communications setup.
Select Parity No. Data Bits Select StopBits Sel. Interface
Info/Help
Error Counts PowerUp Counter
Support Phone#
Logout Version No
Restore Defs.
Language Select
Please call Badger Meter's Technical Support department at (877) 243-1010 for questions related to programming and set-up.
35
(This page intentionally left blank)
Badger® and M-Series® are registered trademarks of Badger Meter, Inc.
Please see our website at
www.badgermeter.com
for specifi c contacts.
Copyright © Badger Meter, Inc. 2009. All rights reserved.
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
Loading...