Badger Meter Magnetoflow Operating Manual
Magnetoflow
Mag Meter
®
Sanitary Meter
with Model Primo
®
3.1
Installation &
Operation Manual
IOM-104-02
BadgerMeter,Inc.
®
53400-104
3-09
SCOPE OF THIS MANUAL
This manual contains information concerning the installation, operation and maintenance of Badger’s Magnetoflow
meter models with Primo® Amplifier.
To ensure proper meter performance, the instructions given in this
manual should be thoroughly understood. Keep a copy of this manual
in a readily accessible location for future reference.
®
electromagnetic flow
TABLE OF CONTENTS
System Description ........................................................................ 2
Unpacking and Inspection ............................................................. 2
Transportation and Handling ......................................................... 2
Meter Installation ............................................................................ 3
Specifications - Detector ............................................................... 5
Grounding ....................................................................................... 6
Specifications - Amplifier ................................................................ 6
Wiring .............................................................................................. 7
Programming ................................................................................... 9
Unit of Measure .......................................................................... 9
Full Scale Setting (Maximum Flow) ......................................... 10
Low Flow Cutoff ........................................................................ 10
Empty Pipe Detection ............................................................... 11
Flow Direction ........................................................................... 11
Filter Dampening ...................................................................... 12
Error List (Messages) .............................................................. 12
Resetting of Totalizers ............................................................. 12
Analog Outputs ......................................................................... 13
Pulse Outputs ........................................................................... 14
Wiring of AMR unit to Mag ....................................................... 14
Frequency Output .................................................................... 15
Flow Alarms .............................................................................. 15
Detector Factor Field Calibration ............................................ 15
Accuracy Test .......................................................................... 16
Meter/Pipe Size ........................................................................ 16
Password Protection ................................................................ 16
Language Selection ...................................................................... 16
Troubleshooting ............................................................................ 17
Error Message Explanation ......................................................... 18
Board Assembly Replacement .................................................... 19
Fuse Replacement ....................................................................... 19
All Badger’s Magnetoflow mag flow meters are factory tested and
calibrated. A calibration certificate is included in the shipment of each
meter.
UNPACKING AND INSPECTION
Magnetoflow mag flowmeters are shipped in special shipping containers. Upon receipt of the meter, perform the following unpacking
and inspection procedures. If damage to the shipping container is
evident, be present when the meter is unpacked.
A) Carefully open the shipping container following any instruc-
tions that may be marked on the exterior. Remove all
cushioning material surrounding the meter.
B) Retain the shipping box and all packing materials for possible
use in reshipment or storage.
C) Visually inspect the meter for any physical damage such as
scratches, loose or broken parts, or any other sign of damage
that may have occurred during shipment.
NOTE: If damage is found, request an inspection report by
the carrier’s agent within 48 hours of delivery. Then file a
claim with the carrier. A formal claim for equipment
damaged in transit is the responsibility of the customer.
D) Verify that the meter received is consistent with the product
ordered. The detail on the product labels on the detector and
the amplifier should help this verification.
E) All detectors with PTFE liner are shipped from the factory with
a liner protector. This protector maintains the proper form of the
PTFE material and protects it during shipping and storage. Do
not remove this protector until you are ready to install the unit.
F) Storage: If the meter is not to be immediately installed, store
it in its original container in a dry, sheltered location. Storage
temperature: -4 to 158 °F (-20 to 70 °C)
METER INSTALLATION
METER LOCATION GUIDELINES
The following are several guidelines for determination of a good
location for meter installation:
SYSTEM DESCRIPTION
Magnetoflow® electromagnetic flow meters are intended for fluid
metering in most industries including water, wastewater, food and
beverage, pharmaceutical and chemical.
The basic components of an electromagnetic flow meter are two: 1)
The Detector; which includes the flow tube, isolating liner and
measuring electrodes, and 2) the Amplifier, which is the electronic
device responsible for the signal processing, flow calculation, display
and output signals.
Detector
The materials of construction of the wetted parts (liner and electrodes) should be appropriate for the specifications on the intended
type of service. Review of the compatibilities consistent with the
specifications is recommended.
Primo
Temperature Ranges
In order to prevent damage to the meter, the maximum temperature
ranges must be observed.
Primo® Amplifier
Ambient temperature: -4 to 140°F (-20 up to +60°C)
Detector
Fluid temperature: -40 to 311°F (-40 up to +155°C)
Outdoor Installations - Primo Amplifier
The Primo Amplifier can be installed outdoors but with a few
requirements:
1. The ambient environment must not be out of the temperature
ratings for the unit. (-4 to 140 degrees F)
2. The Primo must be protected to some degree from the outside
elements. At a minimum, a roof or shield of sorts should be
fabricated over the unit to protect the LCD display from the
sunlight. It will also keep the unit out of the possibility of a hard
sustained rain which could cause moisture to get into the unit. An
alternative approach would be to simply mount the unit in a
“Hoffman style” outdoor enclosure, eliminating the potential of
either issue arising.
If an indoor environment is within 250 feet of the Mag meter
installation, consideration should be given to increase the cable
length and mount the Primo indoors.
2
Chemical Injection Applications
For water line applications with a chemical injection point, the meter
should be installed upstream of the chemical injection point to
eliminate any issues with the meter performance. If an upstream
location is not possible for the meter, consider moving the injection
point downstream of the meter location. If the meter must be installed
downstream of the chemical injection point, the distance between
these (2) locations must be significant; frequently 50 - 100 feet.
When the solution made up of the water and the injected chemical
reach the Mag meter, it must be a complete homogeneous mixture.
If too close, the Mag meter will sense (2) different liquids (conductivity
different for each) and will be confused as to how to process the
information. Many other factors such as the type of injection method,
(spaced bursts versus continuous stream of drops), or whether the
chemical is injected in a liquid or gas form, can cause a wide variation
in the distance required from one application to another.
Due to this wide range of factors, it is difficult to specify a distance that
will always work for any application without establishing a value far in
excess of what would usually be required. Please contact Badger
Meter's Technical Support at 1-800-616-3837 with your application
detail and they can assist in determining if the Mag meter should
properly perform. As noted, the meter may require 50 - 100 feet from
the injection point to assure the complete homogeneous state.
Submersible Option
If the meter is to be installed in a meter vault, it should be installed to
be sure the amplifier is not inside the vault.
Other Considerations
Avoid all pipe locations where the flow is pulsating, such as in the outlet
side of piston or diaphragm pumps.
Avoid locations near equipment producing electrical interference
such as electric motors, transformers, variable frequency, etc.
Install the meter with enough room for future access for maintenance
purposes.
The mag meter isolating liner is not intended to be used as gasket
material. Standard gaskets (not provided) should be installed to ensure
a proper hydraulic seal. When installing the gaskets, make sure they are
properly centered to avoid flow restriction or turbulence. Do not use
graphite or any electrically conductive sealing compound to hold the
gaskets in place during installation. This could affect the reading
accuracy of the measuring signal.
STRAIGHT PIPE REQUIREMENTS
For optimum accuracy performance, it is required to provide sufficient inlet and outlet straight pipe runs. An equivalent to 3 diameters
of straight pipe is required on the inlet side, and 2 diameters on the
outlet side. There are no special requirements for standard concentric pipe reducers.
MAGNETOFLOW MAG FLOWMETER
D (Pipe Size)D (Pipe Size)
FORWARD FLOW
chines, etc. Be sure both ends of signal cable are securely fastened.
Run power and signal cables in separate conduit.
METER ORIENTATION
Magnetoflow Mag Meters can operate accurately in any pipe line
orientation.
However, the most recommended installation position is vertical
piping, with the the liquid flowing upward.
FIG. 1 VERTICAL PIPE MOUNTING
HIGHLY RECOMMENDED
This installation practice ensures two objectives:
· The pipe remains completely full of liquid, even at low flow, low
pressure applications with a discharge to the atmosphere.
· Solid build-ups or sediments that could be part of the process
fluid will not deposit or accumulate on the liner and/or electrodes.
The model Magnetoflow® Sanitary meter is designed to measure flow
in bi-direction only. Carefully observe the "forward flow" label
attached to the meter body and install the meter accordingly.
PIPING CONFIGURATION
Appropriate piping arrangements should be provided to ensure
the meter is not exposed to extreme pipe vibrations. The piping
arrangements should include appropriate pipe supports.
For optimum accuracy performance, it is required to provide
sufficient inlet and outlet straight pipe runs. An equivalent of 3
diameters of straight pipe is required on the inlet side of the
meter, and 2 diameters on the outlet side, measured from the
center of the meter body.
Avoid installing the detector close to flow disturbance generating
valves and fittings.
Do not install the detector in the outlet side of Piston or
Diaphragm type pumps. Avoid all pipe locations where the flow is
pulsating. Avoid installing the detector in the suction side of any
pumps; possible creation of vacuum can affect meter
performance or cause damage to the PTFE liner.
TEMPERATURE
Note: Environmental temperature of installation is not to exceed
maximum specification of 122°F (50°) for the Primo amplifier.
ELBOW
CHECK VALVE
GLOBE VALVE
BUTTERFLY VALVE
PUMP
TEE
GATE VALVE
(FULLY OPEN)
MINIMUM STRAIGHT PIPE
3 x D
MINIMUM STRAIGHT PIPE
7 x D
MINIMUM STRAIGHT PIPE
STANDARD CONCENTRIC
REDUCERS
(NO DISTANCE REQUIRED)
2 x D
ELBOW
TEE
ANY VALVE
By using pipe reducers, a smaller meter size can be mounted in larger
pipeline sizes. This may also increase low flow accuracy performace.
In order to minimize flow disturbances and excessive loss of head,
custom fabricated pipe reducers must have a minimum slope angle
of 15 degrees. If this is not possible, install the custom pipe reducers
as if they were fittings, leaving the minimum straight pipe required.
Mounting Location
The detector should never be installed on the suction side of a pump
where a vaccuum exists to eliminate the possibility of damage to the liner.
If vibration exits on the pipeline, secure the piping before and after
the meter. If a strong vibration exists, the amplifier should be mounted
remotely. Do not install cables near power cables, electrical ma-
GLOBE VALVE
NEEDLE VALVE
CHECK VALVE
PUMP
ELBOW
GATE VALVE
(FULLY OPENED)
BALL VALVE
UPSTREAM
TEE
5-7 D
STRAIGHT PIPE RUN
(ANY POSITION)
PIPE REDUCERS
NO REQUIREMENT
DOWN STREAM
2 D3 D
ELBOW
TEE
ANY VALVE
NO PUMPS
3
PARTIALLY FILLED PIPE SITUATIONS
FLOW
FLOW
FLOW
FLOW
Magnetoflow® mag meters are designed to operate in closed, full
pipes.
It is relatively common to encounter situations where the process
pipe will remain momentarily partially filled due to certain hydraulic
conditions. Examples of this include discharge to the atmosphere
(lack of back pressure), insufficient line pressure, gravity flow
applications, etc.
WRONG
FLOW
WRONG
FLOW
RIGHT
FLOW
RIGHT
FLOW
To eliminate the negative effect of these situations on the
performance of the mag meter, observe the following guidelines:
· Avoid installing the detector in the highest point of the pipe line
· Do not install the detector in vertical, downward flow sections
of the pipe
· ON/OFF valves should ALWAYS be located on the downstream
side of the meter
· Select the recommended vertical orientation with flow upwards
whenever possible
· Make sure that the flow range of the meter size selected is
consistent with the application flow range
To minimize the possibility of partially full pipe flows in horizontal,
gravity or low pressure applications, it is recommended to create a
pipe arrangement as shown in the figure below. This arrangement
ensures the detector remains full of liquid at all times.
Open Discharge
Horizontal Installation
Open Discharge
Horizontal
4
3.94"
3.94"
Meter with junction box for
®
D
remote Primo
converter
B
A
C
Flow RangeEst. Weight
ABC Dwith Primo GPM LPM
inches mm inch mm inch mm inch mm inch mm Lbs Kg Min Max Min Max
3/8”10 7.1 180 .992 25.2 2.8 70 8.3 210 12 5.5 0.034 11.4 0.13 43
1/2”15 7.1 180 .992 25.2 2.8 70 8.3 210 12 5.5 0.06 20 0.23 76
3/4”20 7.1 180 .992 25.2 2.8 70 8.3 210 12 5.5 0.13 45.4 0.52 171
1” 25 7.1 180 1.984 50.4 2.8 70 8.3 210 13 6 0.24 80 0.92 305
1 1/2” 40 7.9 200 1.984 50.4 3.5 89 9.3 235 15 7 0.6 181 2.1 687
2” 50 7.9 200 2.516 63.9 4.1 104 9.8 250 17 7.5 1.0 323 3.7 1223
2 1/2” 65 10.6 270 3.047 77.4 5.1 129 10.6 270 20 9 1.5 504 5.8 1910
3” 80 10.6 270 3.579 90.9 5.5 140 11.0 280 23 10.5 2.2 727 8.3 2751
4” 100 10.6 270 4.682 118.9 6.3 160 11.8 300 24 11 4.0 1292 14.8 4892
SPECIFICATIONS
Flow Range: 0.1 - 33 fps (0.03-10 m/s)
Sizes: 3/8" to 4" (10 to 100 mm)
Min. Conductivity:
Accuracy:
≥ 0.5% accuracy of rate from .1-1 fps.
≥ 0.25% accuracy of rate from 1-33 fps.
≥ 0.5 micromhos/cm
Electrode Material: Alloy C
Liner Material: PTFE
Max. Fluid Temperature: 311°F, (155°C)
Pressure Limits: 150 psi (10Bar)
Coil Power: Pulsed DC
Ambient Temperature: -4°F to 122°F, (-20°C to 50°C)
Meter Enclosure Material: Stainless Steel 316
End Connections: Tri-clamp (sizes 1"-4" per ISO 2852)
Junction Box Enclosure Protection: Stainless Steel, Nema 4X
Cable Entries: 1/2" NPT Cord Grip
Remote Amplifier Enclosure: NEMA 4
PRIMO® AMPLIFIER (3.1 ELECTRONICS)
11.7"
7.75"
298mm
197mm
SPECIFICATIONS
Power Supply: 85-265 VAC, 45-65 Hz
Power Consumption: 20W
Accuracy: ± 0.25% accuracy of rate from 1-39.4 fps.
Repeatability: 0.1%
Minimum Fluid Conductivity: 5.0 micromhos/cm
Flow Direction: Unidirectional or bidirectional, 2 separate
totalizers (programmable)
Analog Outputs: 0/4-20mA, 800ohms Max Load
Ouput Frequency: Scaled Pulse output, (open collector) Max
5Khz
Digital Outputs:
Voltage sourcing transistor, 24VDC, 100mA max
(3) AC electro-mechanical relays, 48VAC, 0.5 amp max
± 0.5% accuracy of rate from 0.1-1.0 fps.
9.68"
246mm
25mm
1"
4.96"
126mm
Mounting Bracket for
Remote Configuration
Outputs: All ouputs are short circuit safe
Noise Dampening: Programmable from 1 to 6
Pulse Width: Programmable up to 500ms
Galvanic Isolation: ≤ 500V
Zero-point Stability: Automatic correction
LCD Display: 4 lines x 16 character back-lit alphanumeric
Displays (2) Totalizers, Flow Rate, Alarm conditions
Housing: Cast aluminum, powder coated paint
Housing Rating: NEMA 4X
Mounting: Detector mount or remote mount (bracket supplied)
Cable Connection: 1/2" NPT Cord Grip
Ambient Temperature: -4 to 140° F (-20 to 60° C)
Serial Communication: RS232
5
WIRING
At installation, be sure to comply with the following requirements:
IMPORTANT!
• Disconnect power to the unit before attempting any
connection or service to the unit
• Do not bundle or route signal lines with power lines
• Keep all lines as short as possible
• Use twisted pair shielded wire for all output wiring
• Observe all applicable local electrical codes
For the AC power connections use three wire sheathed cable with
overall cable diameter of 0.2" to 0.45" (5mm to 12mm). For signal
output use 18 to 22 gauge (0.25 mm
Overall cable diameter between 0.12" to 0.35" (3mm to 9mm).
WIRING FOR REMOTE PRIMO® CONFIGURATION
Wiring between the detector and the Primo amplifier comes complete
from the factory. If your installation requires the use of conduit, the
following are recommended steps for wiring of the detector to the
amplifier.
1. Remove the junction box lid. Carefully remove the wires connected
to the terminal blocks that run to the Primo amplifier. Note which
wire goes into which terminal. The chart below may be of assistance for reference of wire color and terminal connection.
2. Run cable through conduit from Primo amplifier location, retaining
the wiring of the cable to the amplifier as supplied.
2
to 0.75mm2) shielded wire.
Remote style Primo Amplifier models can be ordered with longer
cable than our standard stock lengths of the standard cable; 15, 30,
50 and 100 feet. The following chart shows the cable style options
and the maximum flow medium temperature that can exist in the
application environment at a given length of that cable.
3. Complete conduit assembly on both ends and rewire cable into
junction box as wired when received. See wiring diagram below.
Connection No. Description Wire color
11 Coil Green
12 Coil Yellow
13 Main Shield Yellow/green
45 Electrode White
44* Electrode Shield Black
46 Electrode Brown
40 Empty Pipe Pink
44* Empty Pipe Shield Black
*Connections with the No. 44 are lying on the same potential
Wiring for Remote Primo Configuration
shield (black)
pink
brown
shield (black)
white
yellow/green
yellow
green
44
40
44
46
44
45
13
12
11
green
yellow
yellow/green
white
shield (black)
brown
pink
shield (black)
13 12 11
45
44
46
44
40
44
6
Loading...