Badger Meter MC4000 User Manual
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 Dierence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
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.
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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
8
1
7
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
2
33
456
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MODEL NUMBERS
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
–
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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
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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.
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DIMENSIONS
CB
BA
D
DIMENSIONS
A
Figure 3: MC4000 monitor
A B C
8.70 in. (221 mm) 3.62 in. (92 mm) 1.62 in. (41 mm)
C
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)
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CONNECTIONS
CONNECTIONS
T1T2
2
E-
10 mV
Flow
S+
E+
5
3
7
11 V
to GND
Sensor
Excitation
Pt-100
S-
2
8
T2 T1
1
3
2
4
5
8
1
6
7
GND
GND
4-20 mA
P2 RPM Pulses
4 5
4
3
1
6
GND
4-20 mA
(+) (-)
P1
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.
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OPERATION
OPERATION
ESC
MENU
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
OK
ON
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.
MENU
ESC
OK
ON
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
ON
OK
MENU
SET
ESC
OFF
ON
MENU
OK
SET
OFFSET
OFFSET P1 SET
OFFSET P1 RES
OFFSET P2 SET
OFFSET P2 RES
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