Badger Meter M5000 Installation Guide
M-Series® Mag Meter
Model M-5000
IOM-832-01 (12-10)
PN: 53400-832 Rev. 1
IMPORTANT:
This manual contains important information.
READ AND KEEP FOR REFERENCE.
Installation &
Operation Manual
Model M-5000 Mag Meter
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Installation & Operation
Table of Contents
Safety Precautions and Instructions ...............................................................................................5
System Description...........................................................................................................................5
Unpacking and Inspection ...............................................................................................................5
Meter Location, Orientation and Applications ..............................................................................8
Pipelines and Fluid Flow ................................................................................................................................................8
Meter Orientation ...........................................................................................................................................................8
Pipe Reducer Requirements ..........................................................................................................................................10
Meter/Pipeline Connection Gaskets ............................................................................................................................................................................................................................. 13
Meter Grounding ................................................................................................................................................................................................................................................................. 14
Conductive Pipe Grounding ............................................................................................................................................................................................................................................ 14
Non-Conductive Pipe Grounding .................................................................................................................................................................................................................................. 14
Amplifier Mounting Configuration Options .................................................................................................................14
Meter Mount Configuration ............................................................................................................................................................................................................................................ 14
Remote Mount Configuration ........................................................................................................................................................................................................................................ 15
Submersible Option .......................................................................................................................................................15
Wiring ..............................................................................................................................................................................15
Wiring Safety ......................................................................................................................................................................................................................................................................... 15
Opening the M-5000 Cover ............................................................................................................................................16
Power ...............................................................................................................................................17
Battery .............................................................................................................................................................................17
Battery Life ............................................................................................................................................................................................................................................................................. 17
Battery Replacement ......................................................................................................................................................17
Remote Mount Installation ............................................................................................................................................19
Mount Bracket to Amplifier .............................................................................................................................................................................................................................................19
Wiring Configuration .........................................................................................................................................................................................................................................................19
Wiring for Remote Configuration .................................................................................................................................................................................................................................. 19
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Model M-5000 Mag Meter
Configuring Output ............................................................................................................................................................................................................................................................ 21
Circuit Board Diagram .......................................................................................................................................................................................................................................................21
Digital Output Wiring Diagrams .................................................................................................................................................................................................................................... 22
Programming the M-5000..............................................................................................................23
Function Buttons ............................................................................................................................................................23
Display .............................................................................................................................................................................23
Battery Levels ........................................................................................................................................................................................................................................................................ 23
Display Menu Screen Hierarchy Structure ....................................................................................................................24
Security ...........................................................................................................................................25
Setting a PIN ...................................................................................................................................................................25
M-5000 Main Menu Programming Options ..................................................................................27
Maintenance ...................................................................................................................................38
Cleaning the Flow Tube and Electrode .........................................................................................................................38
Troubleshooting .............................................................................................................................39
Errors & Warnings ...........................................................................................................................................................40
Detector Specifications ..................................................................................................................41
Amplifier Specifications .................................................................................................................42
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Installation & Operation
Amplifier
Detector
®
Safety Precautions and Instructions
Some procedures in this manual require special safety considerations. In such cases, the text is emphasized with
the following symbols:
Symbol Explanation
When attached to the product, this symbol indicates a potential hazard. Review
the documentation to determine the nature of the potential hazard and any
required actions or precautions.
Warning indicates the potential for severe personal injury, death or substantial
property damage. Comply with the instructions and proceed with care.
Caution indicates the potential for minor personal injury or property damage.
Comply with the instructions and proceed with care.
System Description
The Badger Meter M-Series® model M-5000 electromagnetic ow meter is intended for uid metering in most
industries including water, wastewater, food and beverage, pharmaceutical and chemical.
The basic components of an electromagnetic ow meter are:
• The detector, which includes the ow tube, isolating liner and measuring electrodes.
• The amplier, which is the electronic device responsible for the signal processing, ow calculation, display and output signals.
The construction materials of the wetted parts (liner and electrodes) should be appropriate for the specications
on the intended type of service. Make sure to review all of the compatibilities consistent with the specications.
Each meter is factory tested and calibrated. A calibration certicate is included with each meter.
Unpacking and Inspection
Follow these guidelines when unpacking the M-Series equipment.
• If a shipping container shows any sign of damage, have the shipper present when unpacking the meter.
• Follow all unpacking, lifting and moving instructions associated with the shipping container.
• Open the container and remove all packing materials. Store the shipping container and packing materials
in the event the unit needs to be shipped for service.
• Verify that the shipment matches the packing list and order form.
• Inspect the meter for any signs of shipping damage, scratches, or loose or broken parts.
Note: If the unit was damaged in transit, request an inspection report from the carrier within 48 hours. A
claim must be led with the carrier, and contact Badger Meter for appropriate repairs or replacement.
• All detectors with polytetrauoroethylene (PTFE) liners are shipped with a liner protector on each end to
maintain proper form of the PTFE material during shipping and storage.
Note: Do not remove the liner protectors until installation.
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Model M-5000 Mag Meter
®
• Storage: If the meter is to be stored, place it in its original container in a dry, sheltered location. Storage temperature ranges are: -40°F to 160°F (-40°C to 70°C).
Rigging, Lifting and Moving Large Units
When rigging, lifting or moving large units, follow these guidelines.
DO NOT lift or move a meter by its amplier, junction box or cables.
Use a crane rigged with soft straps to lift and move meters with ow tubes that are between two inches and
eight inches (50 mm and 200 mm). Place the straps around the detector body, between the anges, on each side
of the detector.
Use the lifting lugs when lifting meter ow tubes that are 10 inches (250 mm) in diameter or larger.
®
Place straps between anges. Use lifting lugs with 10-inch or larger meters.
Use the sling-rigged method to lift large detectors into a vertical position while they are still crated. Use this
method to position large detectors vertically into pipelines.
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Installation & Operation
Do not lift a detector with a forklift by positioning the detector body on the forks, with the anges extending
beyond the lift. This could dent the housing or damage the internal coil assemblies.
Never place forklift forks, rigging chains, straps, slings, hooks or other lifting devices inside or through the detector's
ow tube to hoist the unit. This could damage the isolating liner.
Do not lift detector with forklift. Do not lift or rig lifting devices through detector.
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Model M-5000 Mag Meter
Meter Location, Orientation and Applications
The M-5000 provides two amplier mounting options: an integral or meter mount option and a junction box/
remote option.
Meter mount amplier Junction box with remote amplier
Remote Amplier Outdoor Location
The amplier can be installed and operated outdoors. However, it must be protected from the elements, as follows:
• The ambient environment/temperature rating for the unit is -4° F to 140° F (-20° C to 60° C).
• If an indoor location is within 100 feet (30 meters) of the detector, consider increasing the cable length
and mounting the amplier indoors.
• At minimum, fabricate a roof or shield over and/or around the amplier to protect the LCD display screen
from direct sunlight.
Pipelines and Fluid Flow
Take the following precautions during installation:
• Do not install the meter on pipes with extreme pipe vibrations. If pipes are vibrating, secure the piping
with appropriate pipe supports in front of and behind the meter. If vibrations can’t be restrained, mount
the amplier in a remote location.
• Do not install the detector close to pipeline valves, ttings or impediments that can cause ow disturbances.
• For detectors with PTFE liners, do not install the detector on suction sides of pumps.
• Do not install the detector on outlet sides of piston or diaphragm pumps. Pulsating ow can aect meter
performance.
• Avoid installing the detector near equipment that produces electrical interference such as electric motors,
transformers, variable frequency, power cables, etc.
• Verify that both ends of the signal cables are securely fastened.
• Place power cables and signal cables in separate conduits.
• Place the meter where there is enough access for installation and maintenance tasks.
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Meter Orientation
Mag meters can operate accurately in any pipeline orientation and can measure volumetric ow in forward and
reverse directions.
Note: A "Forward Flow" direction arrow is printed on the detector label.
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Installation & Operation
Electrode
Plane
RIGHT
Electrode
Plane
WRONG
Vertical Placement
Mag meters perform best when placed vertically, with liquid owing upward and meter electrodes in a closed,
full pipe.
Vertical placement allows the pipe to remain completely full, even in low flow, low pressure applications, and it prevents solids build-up, sediment deposit and accumulation on the liner and electrodes.
Note: Carefully observe the “Forward Flow” label on the meter body and install the meter accordingly.
Horizontal Placement
M-5000 meters are equipped with an "Empty Pipe Detection" feature. If an electrode mounted in the pipe is not
covered by uid, the meter will display an "Empty Pipe Detection" condition. The meter will send out an error
message and stop measuring ow. When the electrode is again covered with uid, the error message disappears
and the meter will begin measuring.
When installing the meter on a horizontal pipe, mount the detector to the pipe with the ow-measuring electrode axis in a horizontal plane (three and nine o’clock). This placement helps prevent solids build-up, sediment
deposit and accumulation on the electrodes.
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Model M-5000 Mag Meter
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
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)
Straight Pipe Requirements
Sucient straight-pipe runs are required at the detector inlet and outlet for optimum meter accuracy and performance. An equivalent of three diameters of straight pipe is required on the inlet (upstream) side. Two diameters are
required on the outlet (downstream) side.
Pipe Reducer Requirements
With pipe reducers, a smaller meter can be mounted in larger pipelines. This arrangement may increase low-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 ow disturbances and excessive loss of head. If this is not possible, install the custom pipe reducers as if they were ttings
and install the required amount of straight pipe.
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Installation & Operation
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 distance between the meter and
the injection point should be between 50 and 100 feet (15 and 30 meters). The distance must be long enough to
allow the water/chemical solution to reach the meter in a complete, homogeneous mixture. If the injection point
is too close, the meter senses the two dierent conductivities for each liquid. This will likely result in inaccurate
measurements. The injection method – spaced bursts, continuous stream of drips or liquid or gas – can also affect downstream readings by the meter.
Sometimes, due to circumstances, it’s dicult to specify the exact downstream placement distances. Contact
Badger Meter Technical Support to review your application, if necessary.
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Model M-5000 Mag Meter
WRONG
RIGHT
FLOW
FLOW
WRONG
RIGHT
FLOW
FLOW
FLOW
WRONG
FLOW
RIGHT
RIGHT
FLOW
FLOW
RIGHT
Partially-Filled Pipe Situations
In some locations, the process pipe may be momentarily only partially lled. Examples include: lack of back pressure, insucient line pressure, gravity ow applications, etc.
To eliminate these situations, do not install the meter at the highest point of the pipeline.
Do not install the meter in a vertical, downward ow section of pipe.
Always position the ON/OFF valves on the downstream side of the meter.
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Do not install in a vertical, downward position. Position "On/O" valves on downstream side.
To minimize the possibility of partially-full pipe ows in horizontal, gravity or low pressure applications, create a
pipe arrangement that ensures the detector remains full of liquid at all times.
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Installation & Operation
GASKETS RECOMMENDED
Meter Gaskets and Grounding
Gasket and grounding requirements must be considered when determining the meter location, orientation and
application.
Meter/Pipeline Connection Gaskets
Install gaskets (not provided) between the detector's isolating liner and the pipeline ange to ensure a proper
and secure hydraulic seal. Use gaskets that are compatible with the uid. Center each gasket on the ange to
avoid ow restrictions or turbulence in the line.
During installation, do not use graphite or any electrically conductive sealing compound to hold the gaskets.
This could compromise the accuracy of the measuring signal.
If using a grounding ring in the detector/pipeline connection, place the ring between two gaskets. (See Non-
Conductive Pipe Grounding on page 14.)
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Model M-5000 Mag Meter
GASKETS RECOMMENDED
GROUNDING RING
GROUNDING RING
Meter Grounding
Process pipeline material can be either electrically conductive (metal) or not electrically conductive (made of or
lined with PVC, berglass or concrete).
Important: It is essential that the mag meter amplier’s input ground (zero voltage reference) be electrically
connected to the liquid media and to a good, solid earth ground reference.
Conductive Pipe Grounding
To achieve an adequate ground, the meter body MUST be electrically connected to the liquid media. The mag
meter anges are provided with grounding bolts for this purpose.
If the pipe material is electrically conductive, simply install grounding straps between these grounding bolts and
the mating anges.
To ensure a good electrical connection at the mating anges, we recommend that drilling and tapping the
anges and install a grounding screw (not provided).
These grounding straps must be copper wire, at least 12AWG size. They must be connected on both sides (inlet
and outlet) of the detector and to a local, earth ground.
Non-Conductive Pipe Grounding
Important: If the process pipe is not electrically conductive (PVC, berglass, cement-lined pipes or any other
non-conductive material) and the meter was not originally ordered with an optional grounding electrode, install
a pair of grounding rings between the mating anges at both ends of the meter. See the following illustration.
In this case, the grounding straps should be connected to both of the grounding rings and to a good, solid earth
ground. Grounding rings are available in stainless steel. If the uid is too aggressive for stainless steel, order a
meter with the optional grounding electrode in a material compatible with the uid.
Amplier Mounting Conguration Options
There are two conguration options for mounting the amplier. There are many options to accommodate a variety of meter-placement and environmental conditions.
Meter Mount Conguration
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The meter mount conguration has the amplier mounted directly on the detector. This compact, self-contained
conguration minimizes installation wiring.
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