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)
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
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
Chemical Injection Applications ...................................................................................................................................................... 8
Meter Gaskets and Grounding .......................................................................................................................................................9
METER INSTALLATION ................................................................................................................................................................ 9
Remote Mount Amplifi er ............................................................................................................................................................... 10
Remote Mount Amplifi er/Detector Wiring ..................................................................................................................................... 10
AC Power Wiring ........................................................................................................................................................................... 15
AMPLIFIER CONTROLS, CONTROL METHODS AND DATA DISPLAY PROGRAMMING ......................................................16
Card Display and Controls ............................................................................................................................................................ 16
Two Programming Methods .......................................................................................................................................................... 17
Main Screen(s) ............................................................................................................................................................................. 17
Amplifi er Access Switches/Buttons .............................................................................................................................................. 18
How to Program ............................................................................................................................................................................ 19
What to Program ..........................................................................................................................................................................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
Analog Output ............................................................................................................................................................................... 27
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.
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.
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.
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 DetectorM-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 erGPM LPM
inch mm inch mm inch mm inch mm inch mm Lbs Kg Min Max Min Max
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)
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 ΩFrequency 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
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
FullScaleFlowEnter 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.
TransistorSet 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 widthSet for Reverse pulse output.
TransistorFull 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 relaySet 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 AmountSet batch amount for Preset Output.
Solid state relaySet 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#
LogoutVersion 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
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Badger® and M-Series® are registered trademarks of Badger Meter, Inc.
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.