Magnetoflow® |
Sanitary Meter |
Mag Meter |
with Model Primo® 3.1 |
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Installation &
Operation Manual
IOM-104-02
BadgerMeter,Inc. |
53400-104 |
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3-09 |
®
SCOPE OF THIS MANUAL
This manual contains information concerning the installation, operation and maintenance of Badger’s Magnetoflow® electromagnetic flow 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.
TABLE OF CONTENTS |
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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 |
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.
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Primo |
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Detector |
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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.
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 instructions 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:
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.
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MAGNETOFLOW MAG FLOWMETER |
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D (Pipe Size) |
D (Pipe Size) |
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FORWARD FLOW |
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ELBOW |
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TEE |
3 x D |
2 x D |
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GATE VALVE |
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(FULLY OPEN) |
MINIMUM STRAIGHT PIPE |
MINIMUM STRAIGHT PIPE |
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CHECK VALVE |
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GLOBE VALVE |
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7 x D |
STANDARD CONCENTRIC |
ELBOW |
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BUTTERFLY VALVE |
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TEE |
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PUMP |
MINIMUM STRAIGHT PIPE |
REDUCERS |
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ANY VALVE |
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(NO DISTANCE REQUIRED) |
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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-
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.
UPSTREAM |
DOWN STREAM |
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PIPE REDUCERS |
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NO REQUIREMENT |
3 D |
2 D |
ELBOW |
ELBOW |
TEE |
TEE |
GATE VALVE |
ANY VALVE |
(FULLY OPENED)
BALL VALVE
NO PUMPS
GLOBE VALVE
5-7 D
NEEDLE VALVE
CHECK VALVE
PUMP
STRAIGHT PIPE RUN
(ANY POSITION)
3
PARTIALLY FILLED PIPE SITUATIONS
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 |
RIGHT |
FLOW |
FLOW |
WRONG |
RIGHT |
FLOW |
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" |
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3.94" |
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D
A |
Meter with junction box for
remote Primo® converter
B |
C |
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Est. Weight |
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Flow Range |
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A |
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B |
C |
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D |
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with Primo |
GPM |
LPM |
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inches |
mm |
inch |
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mm |
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inch |
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mm |
inch |
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mm |
inch |
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mm |
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Lbs |
Kg |
Min |
Max |
Min |
Max |
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3/8”10 |
7.1 |
180 |
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.992 |
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25.2 |
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2.8 |
70 |
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8.3 |
210 |
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12 |
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5.5 |
0.034 |
11.4 |
0.13 |
43 |
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1/2”15 |
7.1 |
180 |
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.992 |
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25.2 |
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2.8 |
70 |
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8.3 |
210 |
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12 |
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5.5 |
0.06 |
20 |
0.23 |
76 |
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3/4”20 |
7.1 |
180 |
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.992 |
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25.2 |
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2.8 |
70 |
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8.3 |
210 |
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12 |
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5.5 |
0.13 |
45.4 |
0.52 |
171 |
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1” |
25 |
7.1 |
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180 |
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1.984 |
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50.4 |
2.8 |
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70 |
8.3 |
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210 |
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13 |
6 |
0.24 |
80 |
0.92 |
305 |
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1 |
1/2” |
40 |
7.9 |
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200 |
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1.984 |
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50.4 |
3.5 |
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89 |
9.3 |
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235 |
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15 |
7 |
0.6 |
181 |
2.1 |
687 |
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2” |
50 |
7.9 |
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200 |
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2.516 |
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63.9 |
4.1 |
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104 |
9.8 |
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250 |
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17 |
7.5 |
1.0 |
323 |
3.7 |
1223 |
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2 1/2” |
65 |
10.6 |
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270 |
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3.047 |
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77.4 |
5.1 |
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129 |
10.6 |
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270 |
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20 |
9 |
1.5 |
504 |
5.8 |
1910 |
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3” |
80 |
10.6 |
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270 |
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3.579 |
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90.9 |
5.5 |
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140 |
11.0 |
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280 |
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23 |
10.5 |
2.2 |
727 |
8.3 |
2751 |
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4” |
100 |
10.6 |
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270 |
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4.682 |
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118.9 |
6.3 |
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160 |
11.8 |
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300 |
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24 |
11 |
4.0 |
1292 |
14.8 |
4892 |
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SPECIFICATIONS |
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Flow Range: 0.1 - 33 fps (0.03-10 m/s) |
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Pressure Limits: 150 psi (10Bar) |
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Sizes: 3/8" to 4" (10 to 100 mm) |
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Coil Power: Pulsed DC |
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Min. Conductivity: |
≥ 0.5 micromhos/cm |
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Ambient Temperature: -4°F to 122°F, (-20°C to 50°C) |
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Accuracy: ≥ 0.25% accuracy of rate from 1-33 fps. |
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Meter Enclosure Material: Stainless Steel 316 |
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≥ 0.5% accuracy of rate from .1-1 fps. |
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End Connections: Tri-clamp (sizes 1"-4" per ISO 2852) |
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Electrode Material: Alloy C |
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Junction Box Enclosure Protection: Stainless Steel, Nema 4X |
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Liner Material: PTFE |
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Cable Entries: 1/2" NPT Cord Grip |
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Max. Fluid Temperature: 311°F, (155°C) |
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Remote Amplifier Enclosure: NEMA 4 |
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PRIMO® AMPLIFIER (3.1 ELECTRONICS)
11.7" 7.75"
298mm 197mm
9.68" |
25mm |
4.96" |
246mm |
1" |
126mm |
Mounting Bracket for
Remote Configuration
SPECIFICATIONS
Power Supply: 85-265 VAC, 45-65 Hz
Power Consumption: 20W
Accuracy: ± 0.25% accuracy of rate from 1-39.4 fps.
± 0.5% accuracy of rate from 0.1-1.0 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
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 mm2 to 0.75mm2) shielded wire. 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.
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
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.
Wiring for Remote Primo Configuration
44 |
shield (black) |
green |
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pink |
yellow |
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40 |
13 12 11 |
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yellow/green |
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44 |
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brown |
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46 |
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shield (black) |
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44 |
white |
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45 |
white |
45 |
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shield (black) |
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44 |
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brown |
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46 |
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13 |
yellow/green |
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44 |
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yellow |
pink |
40 |
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12 |
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green |
shield (black) |
44 |
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11 |
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6
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