Badger Meter MC4000 User Manual

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Turbine Flow Meter

MC4000 Handheld Hydraulic System Analyzer

TUR-UM-00017-EN-02 (February 2014)

User Manual

Turbine Flow Meter, MC4000 Handheld System Analyzer

Page ii February 2014

User Manual

CONTENTS

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Operating Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

MODEL NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

PRODUCT UNPACKING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Measuring Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Datalogger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

SUPPLEMENTARY MEASUREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Peak & Valley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Pressure Dierence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Two Point Flow Sensor Calibration Using the New Lin Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Three Point Flow Sensors Linearizing Using the New Tab Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

MC4CON SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Menu Tabs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Datalogger Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Page iii February 2014

INTRODUCTION

The MC4000 Handheld System Analyzer has inputs for two pressure sensors, one temperature sensor, one flow sensor and one active pick-up for RPM measurements. The MC4000 allows simultaneous connection of four sensors with the measurements displayed in four individual LCD windows using preselected process units according to US or DIN norms. The display supports English and one of the following languages selected at the time of order. Language choices include Spanish, German, Italian and French.

An internal rechargeable battery powers the MC4000. A green LED indicates a completely charged battery. A fully charged battery permits 4 hours of operation with two pressure sensors connected. With the charger connected the battery charges while also allowing use of the instrument. An optional automobile style power cable is available for operation from a car battery.

When operated in the datalogger mode, the MC4000 stores data in an internal 2.5 MB memory space. Each stored measurement also contains the day, date and from the instruments real time clock.

The MC4CON software utility transfers stored measurements via a USB data port to a Windows PC. The MC4CON program permits bi-directional communication not only for the downloading of recorded data to a PC but also for the uploading of commands from the PC to the MC4000.

All parameters can also be set using the buttons on the instrument’s front panel. Pressure units are programmed in psi or bar. The flow and rpm measurements are scaled using programmable constants. Additionally, three point flow calibration for the turbine sensors are available. When activated the pressure tare function allows offset adjustments and the sets the display to zero at non-zero pressure inputs.

Hydraulic horsepower is automatically calculated from the measured pressure and flow. Horsepower displays as either HP or kW depending on the selected units.

Page 4 Month 2014

INTRODUCTION

Operating Principle

Fluid entering the meter passes through the inlet flow straightener, which reduces its turbulent flow pattern and improves the fluid’s velocity profile. Fluid then passes through the turbine, causing it to rotate at a speed proportional to the fluid velocity. As each turbine blade passes through the magnetic field, the blade generates an AC voltage pulse in the pickup coil at the base of the magnetic pick-up (see Figure 1). These pulses produce an output frequency proportional to the volumetric flow through the meter. The output frequency represents flow rate and/or totalization of fluid passing through the turbine flow meter. For a complete component orientation, see Figure 2.

Figure 1: Schematic illustration of electric signal generated by rotor movement

Flow Direction

Figure 2: Typical cross section of sensor array

1 Pickup Magnetic

2 Sensor Temperature

3 Ring Retaining

4 Support Downstream rotor

5 Rotor Turbine

6 Support Upstream rotor

7 Body Meter

8 Sensor Pressure

456

Page 5 Month 2014

MODEL NUMBERS

MC4000 Handheld System Analyzer

Model

MC4000 Handheld System Analyzer FMC4

Language

English + Spanish 1

English + French 2

English + German 3

English + Italian 4

Power Cord

International 2

North American 3

Flow Sensor

0.4…7 gpm (1.5…26 lpm) SAE 8 1

1…40 gpm (4…151 lpm) SAE 12 2

4…80 gpm (15…302 lpm) SAE 16 3

8…160 gpm (30…605 lpm) SAE 20 4

0.4…7 gpm (1.5…26 lpm) G 1/4 5

1…40 gpm (4…151 lpm) G 3/4 6

4…80 gpm (15…302 lpm) G 1 7

8…160 gpm (30…605 lpm) G 1–1/4 8

Pressure Sensor

None N

870 psi (60 bar) 1

1450 psi (100 bar) 2

3625 psi (250 bar) 3

5800 psi (400 bar) 4

Temperature Sensor

None N

392° F (200° C) 1

–

Page 6 Month 2014

SPECIFICATIONS

Display

Accuracy ±0.1% + 1 digit from midrange.

A to D 16-bit, Linearity ± (1 LSB + 1 digit).

Display

Inputs

Keypad

Power

Memory

Tare Pressure channels P1 and P2 are independently set to zero.

Connections

Indicators Green LED between the two sensor plugs indicates power to the battery charging circuit.

Environmental

Sensors

Accuracy ± 1% of reading @ 32 cSt.

Repeatability ± 0.2%.

Pressure

Maximums

Turbine

Response

Time

Environmental

Graphic LCD display with back light, 128 x 64 pixels. Back light auto-off function.

Flow 10 mV…5V Pressure (P1/P2) Dual 4…20 mA. Temperature (T) Pt-100 –50…500° C. RPM 5…24V active pickup. Range 30…60,000 rpm.

Nine keys on the front. With backlight activated, the display is illuminated for 30 seconds after any key is pressed.

Battery 6V, 2 Ah. Charger 100…240V AC.

A fully charged battery permits about four hours of operation with two pressure sensors connected and the backlight switched off.

2.5 MB of datalogging memory can store up to 80,000 samples in all four signal channels, calculated power, date and time. The sampling rate is selectable from 1 s…120 min.

Peak & valley functions stores the maximum and the minimum values of the P1 and P2 pressure sensors.

Two fast transients recorders with a sampling rate of 1 ms and a capacity of 240,000 measurements monitor pressure sensor P1. The recording trigger threshold is programmable between 0…100%.

Two eight-pin, 12 mm sensor plugs. USB data connection. Battery charging connection.

Ambient Temperature –22…158° F (–30…70° C). Humidity 0…90% non-condensing.

5800 psi (400 bar) maximum 5000 psi (345 bar) maximum for SAE 20 and G 1-1/4 size models.

≤200 ms.

Fluid Temperature –4…300° F (–20…150° C). Ambient Temperature –22…158° F (–30…70° C). Humidity 0…90% non-condensing.

sine wave from turbine. Frequency range 0.5…10 kHz scalable.

P-P

SPECIFICATIONS

Page 7 Month 2014

SPECIFICATIONS

Materials

Turbine Housing 6013-T651 Anodized aluminum.

Turbine Rotor T416 Stainless steel. Rotor Supports 6061-T6 Aluminum. Rotor Shaft T303 Stainless steel. Ball Bearings 440 C Stainless steel. Hub Cones 6061-T6 Aluminum alloy. Retaining Rings 6061-T6 Aluminum alloy. Adapters/Plugs 6061-T6 Anodized aluminum. Seals Buna N.

Pickup Housing 6061-T6 Nickel plated aluminum. Nut T303 Stainless steel. Connector Nickel plated brass.

Temperature Probe Case 12L14 Steel, electroless nickel finish. Nut T303 Stainless steel. Connector Brass. Pressure Sensor Case 300 Series stainless steel. Diaphragm 17-4 PH stainless steel.

Page 8 Month 2014

DIMENSIONS

Figure 3: MC4000 monitor

A B C

8.70 in. (221 mm) 3.62 in. (92 mm) 1.62 in. (41 mm)

Figure 4: MC4000 sensor arrays

SERIES A B C D

SAE 8 (G 1/4) 1.23 in. (31.2 mm) 4.72 in. (120.0 mm) 1.47 in. (37.3 mm) 3.91 in. (99.3 mm)

SAE 12 (G 3/4) 1.50 in. (37.6 mm) 5.08 in. (129.0 mm) 1.80 in. (45.7 mm) 4.24 in. (107.7 mm)

SAE 16 (G 1) 1.96 in. (50.3 mm) 5.87 in. (149.0 mm) 2.20 in. (56.0 mm) 4.64 in. (117.9 mm)

SAE 20 (G 1–1/4) 2.46 in. (62.5 mm) 6.81 in. (173.0 mm) 2.48 in. (63.0 mm) 4.92 in. (125.0 mm)

Page 9 Month 2014

CONNECTIONS

T1T2

E-

10 mV

Flow

S+

E+

11 V

to GND

Sensor

Excitation

Pt-100

S-

T2 T1

GND

4-20 mA

P2 RPM Pulses

4 5

GND

4-20 mA

(+) (-)

Figure 5: MC4000 controls and connections

1 Hole Hardware reset

2 Indicator Battery charging

T2 Connector Auxiliary pressure sensor

T1 Connector Flow, pressure and temperature sensors

3 Keypad Keypad

4 Socket Battery charging

5 Port USB–B

PRODUCT UNPACKING AND INSPECTION

Upon receipt of the product, perform the following unpacking and inspection procedures.

OTE:N If damage to the shipping container is evident upon receipt, request the carrier to be present when the product

is unpacked.

Carefully open the shipping package, follow any instructions that may be marked on the exterior. Remove all cushioning material surrounding the product and carefully lift the product from the package.

Retain the package and all packing material for possible use in reshipment or storage.

Visually inspect the product and applicable accessories for any physical damage such as scratches, loose or broken parts or any other sign of damage that may have occurred during shipment.

OTE:N If damage is found, request an inspection by the carrier’s agent within 48 hours of delivery and file a claim with the

carrier. A claim for equipment damage in transit is the sole responsibility of the purchaser.

INSTALLATION

Check the interior of the meter for foreign material. Ensure the turbine rotor spins freely prior to installation. Additionally check and clear fluid lines of all debris.

Page 10 Month 2014

OPERATION

ESC

Measuring Mode

OTE:N Any reference to the P2 pressure sensor assumes installation of the

optional pressure sensor in the system.

Start the MC4000 by pressing ON OFF. The MC4000 performs a self-test and returns the version number of the firmware and the unit's serial number. Additionally the setup parameters, the battery capacity, date, time and free memory are also available. After the startup routine, the instrument automatically goes into measuring mode.

Four windows divide the screen. The two left windows show pressure measurements. The right upper window measures the temperature and the right lower window shows flow or the rpm. Menu commands select the flow (Q) or the rpm (N). Three dashes - - - in a window indicates the absence of a sensor. A battery symbol in the lower right display corner indicates the battery capacity.

P1 bar

74.32

P2 bar

76.12

Function buttons MENU, ESC and SET

T °C

86.5

Q l/min

38.4

OFF

SET

Pressing MENU accesses the menu commands. Pressing MENU repeatedly scrolls through the menu choices. If MENU is pressed and held, menu items automatically scrolls at one second intervals.

ESC

OFF

Pressing ESC allows backwards menu steps. After the third ESC press, the MC4000 exits the menu and switches to measuring mode.

Pressing SET activates tare in both P1 and P2 pressure channels:

OFFSET P1 SET Set pressure P1 to zero – Tare P1

OFFSET P1 RES Cancel the tare function – No Tare P1

OFFSET P2 SET Set pressure P2 to zero – Tare P2

OFFSET P2 RES Cancel the tare function – No Tare P2

SET

ESC

OFF

SET

ESC

OFF

SET

OFFSET

OFFSET P1 SET OFFSET P1 RES OFFSET P2 SET OFFSET P2 RES

Page 11 Month 2014

OPERATION

P1 bar

P1-P2 bar

83.3

P1 bar

P1-P2 bar

Up and Down Arrow Buttons

Press  or  to select any of following modes:

• Peak & valley, pressure difference, power

• Large display mode for pressure P1 or P2

• Large display mode for temperature

• Large display mode for flow and rpm

124.3

P2 bar

24.1

P1 bar

13.5

PW kW

38.4

82.2

P1 bar

124.3

P2 bar

64.6

P2 bar

108.7

T °C

ESC

OFF

12.3

P2 bar

4.1

P1 bar

82.2

P1 bar

12.3

P2 bar

64.6

P2 bar

4.1

Q l/min

13.55

PW kW

38.4

SET

83.3

Q l/min

13.4

Large display mode selected with . Large display mode selected with .

Left and Right Arrow Buttons

• Pressing  resets the peak & valley memory.

• Pressing  returns the MC4000 to measuring mode.

13.4

T °C

ESC

OFF

SET

Page 12 Month 2014

OPERATION

Pressing MENU opens the instrument’s programming menu. Repeatedly pressing MENU also scrolls through the menu selections available on the display. The MC4000 uses     to select menu parameters and make changes. Pressing OK stores any new settings. After pressing OK, the display responds with DATA STORED. Pressing ESC permits scrolling backwards through the menu choices. After three menu presses the display switches back into measuring mode.

STORE OFF Stop storing data to memory.

DATALOGGER

Selection

STORE ON

STORE OFF

STORE DELETE Deletes all stored data.

Set data recording intervals to one of a number of preset times.

SAVE INTERVAL

Selection

1 s

Fast transients are stored in either of two individually selected memory locations. Each transient contains a maximum 240,000 samples. For example, with a sampling rate of 1 ms (1/1000 of a second) the memory capacity is 240 seconds in each memory location. The recording begins when OK is pressed. To stop recording, press and hold OK for at least five seconds. The minimum recording time is 30 seconds. The DATA STORED message displays automatically by pressing OK which stops data recording.

The SHOW selection displays the stored measurements as a graphic.

1s, 2s, 5s, 15s, 30s, 60s, 120s, 300s, 600s, 1200s, 1800s, 2700s, 3600s, 7200s

NO 1 Show

Start storing data to memory by pressing OK.

TRANSIENTS

Selection

NO. 1 OFF

NO 1 Start

NO 1 Delete

NO 2 Show

TRANSIENTS

Selection

NO. 2 OFF

NO 2 Start

NO 2 Delete

THRESHOLD SIGNAL >10 %

BACKLIGHT LIGHT OFF

Selection

>10%, <10%…>90%, <90%

The recording begins when the signal value is larger than the selected level. When the recording must start at zero signal level, threshold <10% must be selected.

BACKLIGHT OFF The backlight is off.

When the backlight is set to on, the display illuminates for 30 seconds each time any of the

BACKLIGHT ON

buttons is pressed. With the backlight, set to on the power consumption from the battery is larger and reduces battery life.

Page 13 Month 2014

OPERATION

DATE AND TIME

21:32:45 AM

29/03/13

SCALE P1 + 100.000

SCALE P2 + 200.000

Selection

Scaling

for

pressure

sensor

(P1)

Scaling

for

pressure

sensor

(P2)

HH : MM : SS

DD : MM : YY

Use the horizontal arrows to select the flashing digit. Alter the value using the vertical arrows. This parameter sets the full-scale reading at the point the pressure sensor P1 has an output of 20 mA.

Use the horizontal arrows to select the flashing digit. Alter the value using the vertical arrows. This parameter sets the full-scale reading at the point the pressure sensor P2 has an output of 20 mA.

Page 14 Month 2014

SEL. FLOW-RPM

SCALE P2 + 200.000

SELECT OFF

OPERATION

SEL. FLOW-RPM SELECT FLOW

Two Point Linearizing

SEL. FLOW TYPE NEW LIN

SCALE FLOW + 1.23456

DSCALE FLOW + 1.23456

SEL. FLOW - RPM SELECT RPM

SCALE RPM + 1.23456

Three Point Linearizing

SEL. FLOW TYPE NEW TAB

TAB F1 INP +1.23456

TAB Q1 OUT +1.23456

TAB F2 INP +1.23456

TAB Q2 OUT +1.23456

TAB F3 INP +1.23456

Pre-programmed Flow Meters

SEL. FLOW TYPE 25 l/min

SEL. FLOW TYPE 150 l/min

SEL. FLOW TYPE 300 l/min

SEL. FLOW TYPE 600 l/min

SEL. FLOW TYPE 7 GPM

SEL. FLOW TYPE 40 GPM

SEL. FLOW TYPE 80 GPM

SEL. FLOW TYPE 160 GPM

Units

To exit the programming menu into the measuring mode press ESC three times.

DSCALE RPM + 1.23456

UNITS US

LANGUAGE ENGLISH

TAB Q3 OUT +1.23456

Units US or EU

Language ENGLISH or DEFAULT

Page 15 Month 2014

OPERATION

P1 bar

T °C

P1 bar

74.32

P2 bar

76.12

Datalogger

Recording Measurements

The internal memory can save all displayed measurements. The USB data port permits the uploading of the stored data to a PC where for further processing. The internal memory permits 224 individual records with a total capacity of 2.5 MB. Use the MC4000 keyboard to initializes each individual record. After initializing the record location, pressing ESC switches the display into measuring mode. In measuring mode, an M icon indicates an active datalogging session.

74.32

P2 bar

Q l/min

76.12

T °C

86.5

Q l/min

38.4

86.5

38.4

Logging Active

Indication

Datalogging Memory Commands

The first menu screen allows a choice to start, stop or delete the datalogger memory.

DATALOGGER STORE DELETE

DATALOGGER STORE ON

This command erases datalogger memory All records are deleted

This command starts the recording of data at the selected interval rate. Each record automatically adds the date and time from an internal real time clock.

DATALOGGER

Stops recording the datalogging information to memory.

STORE OFF

Page 16 Month 2014

New Datalogging Session

OPERATION

DATALOGGER STORE ON

Recording Interval

The save interval is the time between two consecutive recording cycles. It is set in fixed increments as shown below.

SAVE INTERVAL 1 s

Fast Transients - Pressure Channel P1

For recording of fast transients two memory locations are available. Each location is individually selected. Each transient contains a maximum 240,000 samples. For example with a sampling rate of 1 ms the memory capacity is 240 seconds in each memory location. The recording begins when OK is pressed. To stop recording, press and hold OK for at least ve seconds. The minimum recording time is 30 s. When data recording is stopped by pressing OK, DATA STORED is automatically displayed.

OTE:N An existing transient memory record must be deleted before the new record can start.

The SHOW selection displays the stored measurements as graphics. The X-axis shows the elapsed recorded time, the Y-axis shows 0…100% of the full scale pressure set in the pressure channel P1 parameter setup. Any recording may be stopped by pressing OK before reaching the end of the 240 second maximum record length.

To start the next datalogging session select DATALOGGER STORE ON again and confirm the selection by pressing OK.

Selection

1s, 2s, 5s, 15s, 30s, 60s, 120s, 300s, 600s, 1200s, 1800s, 2700s, 3600s, 7200s

TRANSIENTS NO. 1 DELETE

TRANSIENTS NO. 1 START

TRANSIENTS NO. 1 SHOW

OTE:N The controls for transient 2 work the same way as the controls for transient 1.

Recorded data, in the transient 1 memory location, is deleted by pressing OK at the TRANSIENT NO. 1 DELETE prompt.

Data recording, in the Transient 1 memory location, is started by pressing OK at the TRANSIENT NO. 1 START prompt.

A graphic of the transient 1 data is displayed by pressing OK at the TRANSIENT NO. 1 SHOW prompt.

Page 17 Month 2014

OPERATION

Int = 1ms L = 10% T = 240 s

Int = 1ms L = 10% T = 138 s

Transient Graphics Examples

Record using the full memory capacity. Record terminated after 138 seconds.

Figure 6: Graphical pressure representations

Pressing ESC returns the display to the transients menu allowing selection of show or delete functions.

Summary

Either of two transient memory locations, TRANSIENTS NO 1 or TRANSIENTS NO 2, are selectable. Each memory location has a capacity of 240,000 samples. With a sampling rate of 1 ms, each transient memory location records a maximum 240 seconds of transient data. The following apply to both transient 1 and transient 2 memory locations.

• A new recording can start only when the memory location is erased using the TRANSIENTS NO. 1 DELETE function.

• Select TRANSIENTS NO. 1 START and initiate the recording by pressing OK.

• When TRANSIENTS NO. 1 SHOW is selected the recorded data is shown as a graphic representation.

Threshold

The threshold function defines the level at which pressure recordings begin. For example, if the THRESHOLD SIGNAL is set to >20%, the pressure recording will not begin until the pressure exceeds 20% of the maximum pressure set for that sensor. The threshold is set using a percentage of the maximum value used to scale 20 mA input in the SCALE P1 or SCALE P2 menu item. With threshold set for example at >10% the recording starts when the pressure transducer is sending 5.6 mA of current to the MC4000 display. If scaled for 200 psi, pressure sensor P1 begins recording as soon as the pressure reaches 20 psi.

>10%, <10%…>90%, <90% in steps of 10%

THRESHOLD

Selection

SIGNAL <10 %

At the end of a recording cycle, the display automatically shows the graphics corresponding to the stored data from the P1 pressure transducer.

The recording starts as soon as the input signal exceeds the selected level. For records which have to begin at zero signal level, the value <10% has to be used.

Page 18 Month 2014

SUPPLEMENTARY MEASUREMENTS

bar

P1-P2 bar

38.4

86.56

bar

P1-P2 bar

38.4

24.12

Power (HP) =

1720

Pressure (psi) x Flow (gpm)

Power (kW) =

600

Pressure (bar) x Flow (lpm)

1720

1450.4 (psi) x 52.84 (gpm) = 44.56 HP

600

100 (bar) x 200 (lpm)

= 33.33 kW

SUPPLEMENTARY MEASUREMENTS

Peak & Valley

While the MC4000 instrument is in operation, the maximum and minimum pressure measurements from both pressure transducers P1 and P2 record automatically. Pressing UP or DOWN writes the measurements to the display.

Pressing UP displays the maximum values recorded by pressure sensors P1 and P2. The small arrows on the display points up, indicating displayed readings are the maximums (see Figure 7). Pressing DOWN recalls the minimum values of P1 and P2. The small arrow on the display points down, indicating displayed readings are the minimums (see Figure 7).



124.32

P2 bar

Pressure Dierence

The upper right quadrant of the display shows the pressure difference between pressure transducer P1 and P2. Stored maximum and minimum readings show in the left side quadrants of the display (see Figure 7).

Power

The lower right quadrant shows the instantaneous power reading in either HP or kW. The pressure units are either psi or bar, temperature readings are in either º F or º C.

It is important that the pressure entries and scaling use consistent units of psi and º F for US measurements or bar and º C for EU measurements. Unpredictable results occur if the pressure and temperature units are mismatched.

Power Calculations

13.55

PW kW

Figure 7: Pressure display screens



124.32

P2 bar

13.55

PW HP

The power calculation

Examples

US–When programmed in US units of pressure (psi) and flow (gpm), the power is calculated in HP. Pressure = 1450.4 psi Flow = 52.84 gpm

Power (HP) =

DIN–When programmed in DIN units of pressure (bar) and flow(lpm), the power is calculated in kW.

Pressure = 100 bar Flow = 200 lpm

Power (kW) =

Page 19 Month 2014

SUPPLEMENTARY MEASUREMENTS

Maximum Frequency

Maximum Flow Rate

DSCALE

Input Frequency x SCALE

765 Hz

80 gallons

= 0.1046

SCALE =

2632 Hz

7 gallons

= 0.0026596

Two Point Flow Sensor Calibration Using the New Lin Function

The MC4000 flow sensor output signal is a frequency that is proportional to the rate of flow. The MC4000 monitor uses the frequency information to calculate volumetric flow rate and total flow. The raw frequency from the turbine flow sensor requires scaling by a constant in order to achieve a display reading in the required flow units. The MC4000 refers to this constant as the SCALE defined as follows.

SCALE =

The MC4000 menu contains two scaling parameters. They are the already defined SCALE and a scaling divisor referred to as the DSCALE.

Used to shift the decimal point of the displayed reading, the DSCALE setting is particularly useful when the SCALE parameter is a very small number such as in the case of small, high frequency turbine flow sensors.

Calculated flow readings in the MC4000 use the following formula.

Display Reading =

Example

A typical 1 in. turbine flow sensor would have the following characteristics. Maximum Flow = 80 gpm Maximum Frequency = 765 Hz

The scale factor, SCALE, calculation is:

SCALE =

The value for this sensor entered into the SCALE parameter would be 0.1046. In this case a DSCALE value of 1.000 would give correct readings on the MC4000 display.

Using a larger value for DSCALE offers higher resolution and is especially useful when the SCALE value has several leading zeroes in it.

Example

A small turbine flow sensor has the following full scale values. Maximum Flow = 7 gpm Maximum Frequency = 2632 Hz

Because of display limitations, better results are obtained by multiplying the SCALE value by 1000 and using a DSCALE value of 1000.

Page 20 Month 2014

SUPPLEMENTARY MEASUREMENTS

Three Point Flow Sensors Linearizing Using the New Tab Function

Linearization achieves better accuracy of the flow sensor connected to the MC4000. The MC4000 is capable of using up to three linearization points. The points entered are in pairs of frequency values with their associated flow rates. The linear point pairs can be entered using the MC4000 keyboard or from a connected PC.

Linearization Point Frequency (Hz) Flow Rate (Q)

1 Frequency F1 Flow Rate Q1

2 Frequency F2 Flow Rate Q2

3 Frequency F3 Flow Rate Q2

Table 1: Sample linearization table

The linearization menu makes the assignment of both the frequencies and display readings.

Example

Linearization Pair Number Frequency Values Flow Values

Linearization Pair 1 0 Hz 0 lpm

Linearization Pair 2 166 Hz 66 lpm

Linearization Pair 3 630 Hz 150 lpm

Table 2: Sample linearization values

Page 21 Month 2014

MC4CON SOFTWARE

German

Spanish

Italian

MC4CON

French

setup.exe

COM Port Set

MC4CON SOFTWARE

Installation

The MC4000 datalogger connects to a PC by means of a standard USB-A to USB-B cable. The MC4CON software package supports bi-directional communication with a PC. The installation requires about 8MB of disk space under Windows.

When the CD inserted into the PC's DVD/CD drive the MC4CON.exe setup utility opens automatically and installs the MC4CON software on the PC. If the MC4CON.exe setup utility does not start, navigate to the DVD/CD drive and open one of the setup files as shown in Figure 8, and then double click on the setup.exe file to start the installation

MC4CON

Figure 8: Setup folders and setup icon

Communication

MC4CON software allows bi-directional communication between a PC and the MC4000 datalogging utility. The datalogger function is fully programmable from a PC using the MC4000 in download mode. In the upload mode, the PC transfers all recorded data, transients and parameters to the MC4000 where for manipulation. Communications between the MC4000 and a PC is via the USB port that runs at 230,400 baud.

The program automatically searches for an available communications port. When the MC4000 software finds an open port and establishes communications with MC4000, the Connection indicator turns green.

COM Port Set

Connection

Find COM

Stop

Baud

USB

230,400

O.K.

COM

OFF

COM 1 COM 2 COM 3 COM 4 COM 5 COM 6 COM 7 COM 8 COM 9 COM 10

Disconnected and then re-connected the USB cable during communication severs the communication link between the PC and the MC4000. To re-establish communications, select Find COM. The communication will automatically be re-established.

COM Port Set Controls

Find COM Re-establish the communication when interrupted as experienced due to a disconnected cable.

OK Starts the search for an open COM port.

Stop Stop searching for an open COM port.

Connection

Page 22 Month 2014

Turns green when communications are established between the MC4CON software and an MC4000 Handheld System Analyzer.

MC4CON SOFTWARE

Menu Structure

Top Level

Exit

Exit Exits MC4CON software utility.

File

Open Data Table Opens a text file with the file format filename.TX2 containing stored datalogger data.

Save Data Table Stores datalogger data to a text file with the file format filename.TX2.

Open Transient Table Opens a text file with the file format filename.TX1 containing stored transient data.

Save Transient Table Stores transient data to a text file with the file format filename.TX1.

File Read Reads setup data stored in a file with the file format filename.set.

File Save Stores setup data in a file with the file format filename.set.

Exit Exits MC4CON software utility.

COM

Select COM Opens the COM port selection utility.

Select

Measurement Same as pressing Measurement on the MC4000 instrument.

Menu MC4000 Same as pressing MENU on the MC4000 instrument.

Datalogger Same as pressing Datalogger on the MC4000 instrument.

Current Data Table Same as pressing Current Data Table on the MC4000 instrument.

Peak pressure P1 Same as pressing Peak Pressure P1 on the MC4000 instrument.

Info

About Version number and contact information.

Language

Change English / Default (local language, such as Spanish).

Install new Installs new language file into the MC4000.

Menu Tabs

The menu tabs immediately below the main drop downs duplicates the most frequently used item from the Select menu.

Measurement Same as pressing Measurement on the MC4000 instrument.

Menu MC4000 Same as pressing MENU on the MC4000 instrument.

Datalogger Same as pressing Datalogger on the MC4000 instrument.

Page 23 Month 2014

MC4CON SOFTWARE

Menu MC4000 Setup

Measurement Tab

Exit File Com Select Info Language

Menu MC4000 Setup

Measurement

No Sensor

DataloggerMenu MC4000

No Sensor

Read

Figure 9: MC4000 Setup Menu

Read Selection of the Read check box in the measurement screen transfers stored data to the PC from

the MC4000.

Contrast The display contrast is set using the slider bar to the right of the sensor displays.

Page 24 Month 2014

MC4CON SOFTWARE

Menu MC4000 Setup

MC4000 Setup Tab

Under the Menu MC4000 tab, all instrument parameters can be set and then downloaded to the MC4000. The MC4000 also transfers the process parameters and saved data currently displayed on this screen to the PC.

Exit File Com Select Info Language

Measurement

Menu MC4000

Datalogger

Name

Flow-RPM

Language

English Spanish

Sel.Flow type

New-Lin

New-Tab

7 gpm

40 gpm

80 gpm

160 gpm

Backlight

Light o Light on

Sel.Flow-RPM

Select o

Select Flow

Select RPM

RPM

Scale RPM

Dscale RPM

Units

EU US

File

New device File read File save

Device

Menu MC4000 read Menu MC4000 store Menu MC4000 write

New-Lin

Scale RPM

Dscale RPM

New-Tab

Tab F1 INP

Tab F2 INP

Tab F3 INP

Tab Q1 OUTP

Tab Q 2 OUTP

Tab Q3 OUTP

Pressure

Scale P1

Scale P2

Save Interval

1 s 2 s

5 s 15 s 30 s 60 s

120 s 300 s

600 s 1200 s 1800 s 2700 s 3600 s 7200 s

Threshold

SIGNAL > 10% SIGNAL < 10% SIGNAL > 20% SIGNAL < 20% SIGNAL > 30% SIGNAL < 30% SIGNAL > 40% SIGNAL < 40% SIGNAL > 50% SIGNAL < 50% SIGNAL > 60% SIGNAL < 60% SIGNAL > 70% SIGNAL < 70% SIGNAL > 80% SIGNAL < 80% SIGNAL > 90% SIGNAL < 90%

Sel. Flow-RPM Select flow and rpm settings.

Select off Flow measurement display deactivated (display shows ----).

Select Flow Flow measurement is active.

Select RPM RPM measurement is active.

Sel. Flow type Select the flow rate for the currently connected flow sensor.

7 gpm (25 lpm) Default parameters for 7 gpm (25 lpm) flow sensor.

40 gpm (150 lpm) Default parameters for 40 gpm (155 lpm) flow sensor.

80 gpm (300 lpm) Default parameters for 80 gpm (300 lpm) flow sensor.

160 gpm (600 lpm) Default parameters for 160 gpm (600 lpm) flow sensor.

New-Lin Two point calibration for linear flow meters.

Scale Flow Scale the multiplication constant.

Dscale Flow Scale the division constant.

Figure 10: Main MC4000 setup screen

See Two Point Flow Sensor Calibration Using the New Lin Function.

Page 25 Month 2014

MC4CON SOFTWARE

Pressure Pressure parameter settings.

Scale P1 Full scale for the first pressure sensor (P1).

Scale P2 Full scale for the optional pressure sensor (P2).

Save Interval Sampling and recording rate during data collection.

Threshold

The threshold signal level for the P1 (Transient). Defines the point at which transient recording starts.

RPM RPM parameter settings.

Scale rpm Multiplication constant for rpm scaling.

DScale rpm Division constant for rpm scaling.

New-Ta b Three point linearizing of flow sensors.

Example

Tab F1 INP First frequency point. 0 Hz Tab Q1 OUT First displayed flow reading. 0 LPM

Tab F2 INP Second frequency point. 166 Hz Tab Q2 OUT Second displayed flow reading. 38 LPM

Tab F3 INP Third frequency point. 630 Hz Tab Q3 OUT Third displayed flow reading. 150 LPM

Units Flow units are calculated in US or European standard units.

EU Default units are lpm, bar, ° C.

US Default units are gpm, psi, ° F.

Language Selection of English or default (the local country language).

English

Default

Backlight Backlight control.

Light off Backlight is turned off. No instrument backlight.

Light on Backlight is turned on. The display illuminates for 30 seconds when any buttons are pressed.

File Menu MC4000, upper tree switches.

New Device Default setting.

File Read Reads all the menu parameters from a file with the file format filename.set from the MC4000.

File Save Stores all the menu parameters in a file with the format filename.set to the MC4000.

Device Menu MC4000, lower three switches.

Menu MC4000 read Reads the stored MC4000 parameters into the MC4CON software.

Menu MC4000 store Reads the stored MC4CON parameters into the MC4000.

Timer MC4000 write Transfer time and date values from the PC into MC4000.

Page 26 Month 2014

Datalogger Tab

Menu MC4000 Setup

Exit File Com Select Info Language

MC4CON SOFTWARE

Transient 1

Transient 2 Record 1 Record 2 Record 3 Record 4

Status

Stop

Menu MC4000Measurement

Datalogger

Transient 1

Transient 2 Record 1 Record 2 Record 3

Peak data table

Record 4 Record 5 Record 6

Current data table

Record 7

View

Records

2021

1534 368 136 72 520

Date

13.07.2013

16.07.2013

11.07.2013

14.07.2013

Time

15:18:05

08:47:59 07:37:01 07:38:10 07:39:10 15:51:

Upload

Bytes

4068

3072 1472 544 288 2090

Capacity %

50.0

0.0704

0.026

0.0138

0.0995

Figure 11: Datalogger view screen

The datalogger screens allow access to all recorded files shown with date and time as well as controls for instrument data storage. There are also controls to show tabular views of current and peak pressure measurements.

Stop Stops the software screen updating during the data transfer from the MC4000 to the PC.

Peak Data Table Transients data shown in table format.

Current Data Table Datalogger data shown in table format.

View Show all stored transients and records with date, time and byte content.

Upload Read the selected record (Transient 1, 2, Record 1…).

Page 27 Month 2014

MC4CON SOFTWARE

Peak Pressure P1

Data Table Controls

The peak pressure and current data tables use the same controls for manipulating the available data.

Save TXT Stores the table in a *.txt.

Excel open Stores the table in Microsoft Excel *.xls format.

Copy Copies the current file.

Delete Deletes the current file.

Open TXT Opens a previously stored file.

Graph Generates a graphics representation of the current table.

Cancel Exits from the current data table.

Print Prints the current table. The graphic view prints after the table is converted into graphic.

US Uses a decimal point as number separator.

Format

EU Uses a comma as number separator.

Peak Pressure P1 - Data Table

ms Tr. (bar) +1 +2 +3 +4 +5 +6 +7 +8 +9

Date Time Interval 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290

23.07.2013 08:47:59 1000 9,90135 9,90135 9,90135 9,90135 9,90135 9,90135 9,90135 9,90135 9,90135 9,90135 9,90135 9,90135

9,90135 9,90135 9,90135 9,90135 9,90135 9,90135 9,90135 9,90135 9,90135 9,90135 9,90135 9,90135

Save TXT

Excel open

Copy

Delete

Open TXT

Graph

Cancel

Format

12 Lines

Page 28 Month 2014

Figure 12: Peak pressure table

Peak Pressure P1 - Graphics

Peak Pressure P1 Graphics

bar

20 40 60 80 100 120 140 160 180

MC4CON SOFTWARE

Peak Pressure P1 Graphics

07.09.2013 08:07:01

sec

Figure 13: Peak pressure graphics screen

Page 29 Month 2014

MC4CON SOFTWARE

Current Data Table

The current data table shows all four signal channels plus the calculated power:

Current Data Table

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 24 26 27 28 29 30 31 32

Date

11.07.2013

Time 08:46:59 08:47:00 08:47:01 08:47:02 08:47:03 08:47:04 08:47:05 08:47:06 08:47:07 08:47:08 08:47:09 08:47:10 08:47:11 08:47:12 08:47:13 08:47:14 08:47:15 08:47:16 08:47:17 08:47:18 08:47:19 08:47:20 08:47:21 08:47:22 08:47:23 08:47:24 08:47:25 08:47:26 08:47:27 08:47:28 08:47:29 08:47:30

P1 (psi)

200.5

201.5

201.2

200.9

201.3

207.5

209.8

210.1

209.8

209.2

210.7

208.9

209.5

209.9

210.3

212.1

211.9

212.3

210.7

210.5

208.6

209.1

209.9

210.2

210.5

210.9

208.9

208.5

208.2

207.7

P2 (psi)

T (F)

101.72

101.56

101.66

101.84

101.93

101.95

102.01

102.03

102.02

102.05

102.18

102.22

102.35

102.39

102.40

102.44

102.48

102.49

102.60

102.77

102.85

102.93

103.05

103.09

103.15

103.18

103.22

103.25

103.24

Q/N (g/min)

50.0

49.9

48.2

49.1

49.9

48.9

47.9

48.5

48.9

49.0

50.2

49.8

49.2

48.8

49.1

49.0

49.3

49.5

49.4

49.6

49.9

50.2

50.1

49.8

49.6

50.3

49.4

49.1

48.9

49.2

49.4

POW (HP)

5.829

5.846

5.837

5.630

5.746

5.840

5.899

5.843

5.924

5.965

5.960

6.150

6.048

5.993

5.955

6.003

6.043

6.074

6.110

6.052

6.070

6.052

6.103

6.114

6.086

6.070

6.156

6.057

5.964

5.928

5.956

5.965

Save TXT

Excel open

Copy

Delete

Open TXT

Graph

Cancel

Format

46 Lines

Figure 14: Current data table

Current Data Graphics

Automatically generates and loads graphics from the Current Data Table to the display by clicking on Graph.

Graph

Generates graphics from the Current Data Table. The right side of the window shows the scaled values of the measured signals. The maximum and minimum values are the default. Display of all five variables is simultaneous. If required individual variables may be deselected.

Page 30 Month 2014

Current Data Graphics

P2(bar) T(C) Q(l/min) PW(kw)P1(bar) 200 100 1000 100200

0 0 0 0

Current Data Graphics

5 10 15 20 25 30 35 40 45

Time = 45s

MC4CON SOFTWARE

Max

200

Min

Max

200

Min

Max

200

Min

Q/N

Max

200

Min

POW

Max

200

Min

07.09.2013

08:07:01

Defaults

Variable Minimum Maximum

Q/N 0 1000

POW 0 100

Figure 15: Graph of current data

P1 0 200

P2 0 200

T 0 100

Page 31 Month 2014

APPENDIX

Troubleshooting Guide

Symptom Possible Cause Remedy

Meter indicates higher than actual flow rate.

Meter indicates lower than actual flow rate.

Erratic system indication, meter alone works well (remote monitor application only).

Indicator shows flow when shut off.

No flow indication.

Full or partial open position.

Erratic indication at low flow, good indication at high flow.

–Cavitation.

–Debris on rotor support.

–Build up of foreign materials in the meter bore.

–Gas in liquid.

–Debris on rotor.

–Worn bearing.

–Viscosity higher than calibrated.

Ground loop in shielding.

Mechanical vibration causes rotor to oscillate without turning.

Fluid shock, full flow into dry meter or impact caused bearing separation or broken rotor shaft.

Rotor has foreign material wrapped around it.

–Increase back pressure.

–Clean meter.

–Install gas eliminator ahead of meter.

–Clean meter and add filter.

–Recalibrate monitor.

Ground shield one place only. Look for internal electronic instrument ground. Reroute cables away from electrical noise.

Isolate meter.

Rebuild meter with repair kit and recalibrate monitor. Move to location where meter is full on start-up or add downstream flow control valve.

Clean meter and add filter.

No flow indication. Faulty pick-up. Replace pick-up.

System works perfect, except indicates lower flow over entire range.

Meter indicating high flow, upstream piping at meter smaller than meter bore.

Opposite effects of above. Viscosity lower than calibrated.

Meter doesn't respond to any changes in process inputs or keystrokes.

By-pass flow, leak.

Fluid jet impingement on rotor. Change piping.

Processor hang due to communications interruption.

Repair or replace by-pass valves, or faulty solenoid valves.

Change temperature, change fluid or recalibrate meter.

Perform a hardware reset by inserting the end of a paperclip into the hardware reset hole on the left side of the enclosure. See Figure 5.

OTE:N For this procedure to work, the

charger must be disconnected from the MC4000.

Page 32 Month 2014

INTENTIONAL BLANK PAGE

User Manual

Page 33 February 2014

Flo-tech is a registered trademark of Badger Meter, Inc. Other trademarks appearing in this document are the property of their respective entities. Due to continuous research, product improvements and enhancements, Badger Meter reserves the right to change product or system specications without notice, except to the extent an outstanding contractual obligation exists. © 2014 Badger Meter, Inc. All rights reserved.

www.badgermeter.com

Badger Meter MC4000 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Operating Principle

MODEL NUMBERS

SPECIFICATIONS

DIMENSIONS

CONNECTIONS

PRODUCT UNPACKING AND INSPECTION

INSTALLATION

OPERATION

Measuring Mode

Menu

Datalogger

SUPPLEMENTARY MEASUREMENTS

Peak & Valley

Power

Two Point Flow Sensor Calibration Using the New Lin Function

Three Point Flow Sensors Linearizing Using the New Tab Function

MC4CON SOFTWARE

Installation

Communication

Menu Structure

Menu Tabs

Datalogger Tab

APPENDIX

Troubleshooting Guide