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Badger M4000 Magmeter Manual

1. 35 89 _ gal N 1 1 2 0 11 0 7 7 5 191 16 35 00 3 4 2V 65 2 13 5 16 0 19 0 SPECIFICATIONS Flow Range 0 1 to 39 4 ft s 0 03 12 m s Flow Direction Uni directional or Bi directional Sizes 1 4 to 12 6 to 300mm Conductivity Min 5 micromhos cm Accuracy 0 25 of rate for velocities greater than 1 64 ft s 0 50 m s 0 004 ft s 0 001 m s for velocities less than 1 64 ft s 0 50 m s Electrode Materials Alloy C 316 stainless steel gold platinum plated tantalum platinum rhodium Liner Material PFA from 1 4 to 3 8 6 to 10mm PTFE from 1 2 to 12 15 to 300mm soft and hard rubber from 1 to 12 25 to 300mm NSF Listed Models with hard rubberl liner 4 inch and up PTFE liner all sizes Fluid Temperature With remote mounted amplifier PFA PTFE 4 F to 248 F 20 C to 120 C O Max ambient temp of 122 F 50 C Soft amp Hard rubber 32 F to 178 F 0 C to 80 C Max ambient temp of 122 F 50 C 28 15 15 4 6 5 0 191 1845 472 436 198 11 0 58 0 0 177 6 7 170 11445 366 35 89 1515 388 125 57 011 33 0416 125 1267 170 11465 371 39 99 1525 393 155 70 02 89 225 1485 376 43 108 1545 398 220 10 0 89 89 89 110 225 350 575 08 1400 8 2400 3600 5600 8800 12700 22600 35300 50800 24 6 36 4 37 8 3361 5975 9
2. Fuse ratings are listed on the circuit board next to the fuse holders Refer to the M Series Model M 4000 Repair Parts List IRP 211 01 To access and replace fuses 1 Remove display chamber cover Turn the cover counterclockwise to remove it from the amplifier If necessary use a strap wrench 2 Remove the 2 display card screws and washers 3 Tilt card up out approximately 45 degrees at the holding clips 4 Fuses are in the round black fuse holders Use a flat screwdriver to turn the holder cap counterclockwise until the lock tab reaches the opening and the holder and fuse disengage 5 6 Reverse steps 1 to 3 to assemble the unit Amplifier Printed Circuit Board PCB Stack Replacement All M 4000 mag meters operate through printed circuit boards PCBs housed in the amplifier The PCBs are grouped in a stack located behind the display control card in the display programming chamber Because PCBs are complex circuits with all meter functions enabled through multiple links and layers determining the exact board and circuit that is causing a system problem is difficult and usually requires test equipment Should a meter problem occur 1 2 Call Badger Meter at 877 243 1010 and discuss the problem with a Technical Support Specialist If the problem appears to originate in a PCB it will be recommended that the entire PCB stack be removed and returned to Badger Meter a i
3. gravity flow applications etc To eliminate these situations Do not install the meter in the highest point of the pipeline Do not install the meter in a vertical downward flow section of pipe RIGHT ALWAYS locate ON OFF valves on the downstream side of the meter To minimize the possibility of partially full pipe flows in horizontal gravity or low pressure applications create a pipe arrangement that insures the detector remains full of liquid at all times Meter Gaskets and Grounding Two other considerations to meter location orientation and application are gasket and grounding requirements and placement Meter Pipeline Connection Gaskets Gasket s not provided must be installed between the detector isolating liner and the pipeline flange to ensure a proper and secure hydraulic seal Use gaskets compatible with the fluid flow Center each gasket on the flange to avoid flow restrictions or turbulence in the line Do not use graphite or any electrically conductive sealing compound to hold gaskets during installation Measuring signal accuracy could be affected If a grounding ring is used in the detector pipeline connection place the ring between two gaskets See Non Conductive Pipe Grounding section Meter Grounding Process pipeline material can be either electrically conductive metal or not electrically conductive made of or lined with PVC fiberglass or concrete To ensure proper unit ope
4. Avoid installing the detector close to pipeline valves fittings or impediments that can cause flow disturbances 3 For detectors with PTFE liners avoid installing the detector on suction sides of pumps 4 Avoid installing the detector on outlet sides of piston or diaphragm pumps Pulsating flow can affect meter performance 5 Avoid locations near equipment producing electrical interference such as electric motors transformers variable frequency power cables etc 6 Verify both ends of the signal cables are securely fastened 7 Place power and signal cables in separate conduit 8 Place the meter where there is enough access for installation maintenance purposes Meter Orientation Mag meters can operate accurately in any pipeline orientation and can measure volumetric flow in forward and reverse directions NOTE A Forward Flow direction arrow is printed on the detector label Vertical Placement Mag meters attain optimal performance when placed vertically with liquid flowing upward and meter electrodes in a closed full pipe Vertical placement allows the pipe to remain completely full even in low flow low pressure applications and it prevents any solids build up or sediment deposit or accumulation on the liner and or electrodes NOTE Carefully observe the Forward Flow label on the meter body and install the meter accordingly Horizontal Placement In a horizontal piping orientation mount the detec
5. close based on set points Output will open or close during error conditions EmptyPipe Error Output will open or close when the pipe is empty Flow Direction Output will open or close when flow direction changes 34 Digital Out 4 Preset Amount Set batch amount for Preset Output Solid state relay Set point min Set for Flow Set Point output et point max Set for Flow Set Point output utput Type Select N O or N C for any output function None Select Function reset Output Output will open or close when preset amount is reached low Set Point Output will open or close based on set points rror Alarm Output will open or close during error conditions Sets totals to Zero mptyPipe Error Output will open or close when the pipe is empty low Direction Output will open or close when flow direction changes Communications gt Serial Port Select Baud RS232 communications setup elect Parity O Data Bits elect StopBits Sel Interface nio Hal upport Phone Restore Dets Language Select Please call Badger Meter s Technical Support department at 877 243 1010 for questions related to programming and set up 35 This page intentionally left blank Badger and M Series are registered trademarks of Badger Meter Inc Please see our website at TUV www badgermeter com MANAGEMENT SERVICE for specific contacts ISO 9001 Copyright Badger Meter Inc 2009 All rights reserv
6. ej AE A E i F E 22 A ki a w w AL 5 Z PCB Stack in Amplifier 31 REMOVE PCB STACK Disconnect main power to the unit before attempting any device maintenance 1 Remove display programming chamber cover Turn the cover counterclockwise to remove it from the amplifier If necessary use a strap wrench 2 Remove 2 display card screws and washers Place in storage for reuse Tilt display card up out approximately 45 degrees at the holding clips 4 Gently pull card down and out from between holding clips 5 Disconnect display card plug from left side of PCB display 6 Disconnect the Power Coil Electrode and I O plugs and harnesses from the PCB interconnect card Remove the 4 screws holding the PCB stack in the amplifier housing Place in storage for reuse Gently remove the card stack from the amplifier housing Do not tug or pull to remove the stack Ease it out carefully 32 10 11 Carefully wrap and package the PCB stack and display card Send back to Badger Meter Reverse these steps to install a PCB stack When replacing the PCB stack a Be sure to place the two lower feet of the circuit board support along the edges of the amplifier housing b Gently move the stack back into the housing until the to holes at the top mate with the housing The stack is not connected to the circuit board in this picture When placing display card back into PCB
7. installation remember these important points 1 Heed all safety notifications 2 Select a detector location with room for installation and O O N maintenance procedures Use proper lifting rigging and moving procedures for large units Consider the meter environment particularly ambient and process flow temperatures Consider the process pipeline vibrations and its flow characteristics valve and pump locations Meter orientation to the pipeline vertical or horizontal Straight pipe requirements Pipe reducer requirements Special applications and or situations For Remote Mount Units consider 1 2 3 4 Amplifier location Remote amplifier mounting bracket Proper conduit and conduit fittings Wiring and conduit locations REMOTE MOUNT AMPLIFIER NOTE Screws are supplied to attach the remote mount bracket to the amplifier Screws are not supplied to attach bracket at mounting location Remote Mount Amplifier Location Requirements 1 2 3 4 5 A sturdy and safe mounting surface capable of holding the amplifier weight 20 pounds 9 Ko Within the allowable temperature range 4 F to 122 F 20 C to 50 C Access to amplifier covers ports terminals screen and adjustments As close to the detector as possible Determine length and route of cable conduit runs Mount Bracket to Amplifier 1 2 Align bracket mounting holes with amplifier mounting holes Attac
8. katt oan Maes ae cas See eed oe alate 27 DETECTOR SPECIFICATION Soi a ica 29 AMPLIFIER SPECIFICATIONS siniri iia 30 MAINTENANCE atari canas 31 Flow TupeariqiEl6etr6ge C Sarga am o ados 31 FuseTipoac OInOentuy a em yam N span squam qaman a SE h sap p ukun tasa e a E ass suu apu aaa 31 Amplifier PGB Stack Replacelment u D u ce eed een sm aaa a ds o De sa 32 FLOW CHART MENW STROCTURE u a mushu aus usasasass a ESAR aaae 34 SAFETY PRECAUTIONS and INSTRUCTIONS Safety considerations are emphasized by the placement of safety symbol icons on the product or next to important text pictures or drawings throughout this manual The symbols are When and where this symbol is attached to the product it indicates a potential hazard It means that documentation must be consulted to determine the nature of the potential hazard and any actions that need to be taken Warning indicates an action or procedure which if not performed correctly can result in sever personal injury death or substantial property damage Comply with the instruction and proceed with care Caution indicates an action or procedure which if not performed correctly will or can cause minor personal injury or property damage Comply with the instruction and proceed with care Equipment Unpacking Inspection Moving and Return Policies 1 If shipping container damage is evident at delivery have a responsible person present when the meter is unpacked 2 Inspect th
9. meter programming The amplifier program uses three types of screens a List screen an Input Numbers screen and a select ON or Off screen MAIN MENU 00 Select Press to gt Exit this Menu move text up by one line relative to the on screen Meter Setu p arrow for each select press when choosing menu Measurements or sub menu list names I nputs Outputs move text up by one line relative to the arrow for Clear Tota S each select press when selecting a parameter Communications setting from a list I nfo Help increase a number by one digit for each select Logout press when inputting parameter numeric settings Sample List Screen Select Press to move text down by one line relative to the on screen arrow for each select press when choosing menu or sub menu list names move text down by one line relative to the arrow for each select press when selecting a parameter setting from a list decrease a number by one digit for each select press when inputting parameter numeric settings E Switch Button Sample Select ON or OFF Screen The following pages introduce you to the screen formats describe how to maneuver to and through them and provide some specifics about programming terminology and Select Press E to parameters To enter open a menu or sub menu topic at which If possible have access to your amplifier display and controls the arrow is pointing and perform these screen manipulations Select between ON OFF
10. once to go to Chg Password 4 At CHG PASSWORD 16 screen input a password number 5 Or this screen comes up Input the correct password 6 If the wrong number is input INVALID PSWD comes up Press or E once 7 Main Screen appears Press E again 8 PASSWORD 01 screen reactivates Input the correct password Set Flow Rate Unit of Measure and Totalizer Unit of Measure With Main Screen up press E 2 With MAIN MENU 00 active press twice Measurements and then E 3 On the MEASUREMENTS 20 screen press once to place cursor at Flow Unit Press E 4 From FLOW UNITS 21 press or to select a flow unit Press E 5 This type of screen shows for two seconds 6 The screen returns to MEASUREMENTS 20 With the cursor at Exit this Menu press twice to move cursor to Totalizer Unit Press E 7 From TotalizerUnit 22 press or to select a totalizer unit Press E 8 This type of screen shows for two seconds 9 Screen goes back to MEASUREMENTS 20 Set Full Scale Flow Rate Value 1 Press three times to move the cursor to FullScaleFlow Press E 2 At FullScaleFlow 23 input the proper flow Select E to move cursor as described earlier 3 Screen returns to MEASUREMENTS 20 SET LOW FLOW CUTOFF 1 Press four times to place cursor at LowFlowCutOff Press E 2 At LowFlowCutOff 24 screen input a percentage at the 4 And this type o
11. or better Auxiliary Input Wiring Diagram Function Reset MACAUTION oiea n To prevent accidents connect main power only after all other wiring has been completed L Input 1 US o 5 24VDC Common 4 G J Analog Output Wiring Diagrams e Analog Output Loop voltage 18VDC Sourced 750 MAX Function 4 20mA 0 20mA Common 6 0 10mA e Output 1 Functions Forward only Pulse Transistor Output open collector AMR Pulse 24VDC Max Flow Set Point 5W Max Error Alarm Empty Pipe Passive Output Wiring Flow Direction Output 1 3 u 02 External Counter Badger Meter ER8 01 orAMR Device Programmable Common 4 14 The amplifier is a microprocessor device It is important that the power supply be as clean as possible Avoid using power lines that feed heavy loads pumps motors etc If dedicated lines are not available a filtering or isolation system may be required AC wiring is the same for meter mount and remote mount amplifiers 1 Remove AC Wires Port screw from amplifier connections chamber Lay out AC cable and conduit to amplifier Place cable in conduit Strip AC cable back 2 inches 50mm Strip AC wires back 1 4 inch 6mm Attach AC wires to amplifier terminal S OQ ey Black to L White to N Green to G Amplifier O e p 85 265 VAC AC wires p O O 45 65 Hz Oo 7 Connect conduit to amplifier 8 Att
12. pipe voltage reading should be below 3 00 Volts 9 Press once to move cursor to Exit WITH save Press E once to save the setting and return to EMPTY PIPE 15 24 10 In EMPTY PIPE 15 press three times to place cursor at Enable Disable Next press E 11 In EMPTY CONTROL 1G press twice to move cursor to Det OFF E ON Press E once to switch OFF to ON 12 Press once to move cursor to Exit WITH save Press E once to save the setting and return to EMPTY PIPE 15 1 Press E once to move cursor to Main Menu 2 Inthe MAIN MENU 00 press three times to move the crusor to Inputs Outputs Next press E Pulse Output 3 AtIN OUTPUTS 30 press three times to place the cursor at Digital Out 1 Press E 4 InDIG OUTPUT 1 33 press once to move the cursor to Pulses unit Press E You only need to do this if the function of output one 1 is to be Fwd Pulse or AMR 50ms pulse Refer to page 35 Digital Output 1 5 In PULSES UNIT 3D input a proper number as described earlier Press E 6 The screen returns to DIG OUTPUT 1 33 Press or activate twice then press E This is only for Fwd Pulse Refer to page 35 Digital Output 41 5 7 Into screen PULSE WIDTH 3E enter a number Press E 8 The screen returns to DIG OUTPUT 1 33 Press three times then press E SET POINT This is only for Flow Set Point Refer to page 35 Digital Output 1 1 Into screen SE
13. settings The amplifier display chamber cover stays on The other method involves removing the display chamber cover and manipulating the and E push buttons to view and change settings and program desired meter functions and settings AMPLIFIER SCREENS MENUS and PROGRAMMING Amplifier programming requires planning moving and activating the and E selections on three types of menu parameter screens List screen Input Numbers screen and select ON or Off screen MAIN SCREEN S The first screen is the Main Screen It is always displayed when programming functions are not occurring NOTE When programming if no contact is made with switches or buttons for 2 minutes in any parameter the display returns automatically to your programmed Main Screen Two Main Screen Format settings are possible Which setting to use is determined by the fluid Flow Direction through your meter The settings are Uni Directional flow or Bi Directional flow reference page 23 Set Flow Rate Unit of Measure and Totalizer Unit of Measure to program flow units Both main screens display the rate of flow R and flow units Uni Directional Flow Main Screen Uni directional Flow Totalizes Pipe Flow in only one direction the flow direction arrow printed on the detector label reference page 24 Set Flow Direction to program for uni directional flow Uni directional readings on the display main screen are identified as R
14. 3 X 25mm four line 16 character backlit LCD display Measurement F Screen LCD Display Magnet Switches W Push Buttons ha TE Magnet Wand 3 Display screens and screen data are manipulated with magnet switches or push buttons By operating the switches or buttons different screens are accessed program parameters are selected and changed and settings are reprogrammed If no contact is made with switches or buttons for 2 minutes in any parameter the display returns automatically to the Main Screen 16 ACCESS to AMPIFIER SCREENS DATA and PARAMETER PROGRAMMING NOTE The M 4000 can be programmed to meter many flow situations and serve a variety of purposes during a production process To meet diverse needs there are a wide variety of programming options and parameters Your metering requirements probably do not require the use of all program screens options and parameters Your M 4000 amplifier is delivered preprogrammed based on information available at the time the unit was ordered In most instances it will not require any changes Use this section to program flow signal outputs or reprogram your meter to specific requirements Flow measurement and totalizing continues during amplifier programming Two Programming Methods There are two methods for programming In one method a magnet wand is used to manipulate and E switches to view and change screens and program functions and
15. 336 19444 8 73 8 113 6 With meter mounted amplifier PFA PTEE 4 F to 212 F 20 C to 100 C Max ambient temp of 122 F 50 C Soft amp hard rubber 32 F to 178 F 0 C to 80 C Max ambient temp of 122 F 50 C Pressure Limits Max 150 psi 10 bar Ambient Temperature 20 F to 122 F 29 C to 50 C Coil Power Pulsed DC Pipe Spool Material 316 stainless steel Spool Housing Material Carbon steel welded NEMA 4 IP66 Junction Enclosure Material for remote mounted amplifier option Cast aluminum powder coated paint NEMA 4X IP66 Flanges Carbon steel or 316 stainless steel ANSI B16 5 Class 150 RF Grounding Rings optional 2 required 316 stainless steel Meter Size Thickness one ring 1 4 to 10 6 to 250mm 135 8 43mm 10 to 12 250 to 300mm 187 4 75mm Grounding Electrode optional Alloy C 316 stainless steel gold plati num plated tantalum or platinum rhodium Electrical Classification FM approved for Class I Div 1 Groups C D Class II Div 1 Groups E F amp G CSA Certified Pressure Limits Max 150 psi 10 bar Ambient Temperature 4 F to 122 F 320 C to 50 C Locations Indoor and outdoor Altitude Maximum 6500 feet 2000m AMPLIFIER SPECIFICATIONS Detector Mount Amplifier SPECIFICATIONS Power Supply 85 265VAC 45 65Hz Power Consumption 20W Accuracy 0 25 of rate for velocities greater than 1 64 ft s 0 50 m s 0 004 ft s 0 001 m s f
16. AtIN OUTPUTS 30 press once to place the cursor at Analog Output Press E 6 It then switches to SELECT OUT 1 3J Make a selection Press E SELECT OUT 1 3J 4 In ANALOG OUTPUT 31 press once to move the Exit this Menu cursor to Range Select Press E None Forward Pulse AMR 50ms pulse Flow Set Point Error Alarm EmptyPipe Error 5 In RANGE SELECT 3A select a range with the button gt Flow Direction and then press E 7 This type of screen shows for two seconds and then returns to DIG OUTPUT 1 33 6 The screen returns to ANALOG OUTPUT 31 Press twice to move the cursor to Zero Calibrate and then press E Whichever selection is made from screen SELECT OUT 1 IJ the next screen always shows XXXXX SELECTED The screen then returns to DIG OUTPUT 1 33 where you will Connect amp meter to mA analog output pins 5 and 6 have to 1 Select Functions screen 7 In ANALOG ZERO 3B make a selection of Decrease or 2 Screen Z1 appears Increase based on what the amp meter is reading 3 Select another screen Do this until all required select Out 1 35 are 26 8 Press the E button until the amp meter reads the desired No Flow set point The line to the left of the selection rotates as the E button is pressed to show that there is activity AMP METER 15 ANALOG OUTPUT 31 returns with the arrow pointing at Exit this Menu Press E 16 IN OUTPUTS 30 returns with the arrow pointing at Exit this
17. Display verify mark and red stripe are aligned with Number 1 Red Stripe Mark RIP FLOW CHART MENU STRUCTURE In the Flow Chart 1 Each separate screen is inside a box 2 Ifa screen branches an arrow points right and each screen of the branch is in a box 3 When there is text but it s not in a box that signifies a parameter setting and a short explanation is given of the parameter Mark on the chart what parameters need to be set Note parameter settings on the chart Program your amplifier accordingly Keep the chart as a reference for other shifts and personnel and to monitor meter performance Menu Structure Pipe Dia Enter the flow tube diameter Enter the meter calibration factor Select the coil excitation frequency All calibration factors are determined at the Hydr Zero Auto Empty Pipe gt Cal empty pipe Empty pipe detection setup Cal full pipe Enable Disable Chg Password __y Password new Enter 0000 to disable password Rate Unit Select flow rate unit Totalizer Unit Select total volume unit ullScaleFlow Enter full scale flow for the analog output owFlowCutOff Enter the low flow cut off Typically 0 2 low Dir Select uni directional or bi directional flow amping Factor Select as needed 7 33 Digital Input 1 Select function for input Open collector Transistor Select Function Set for Forward pulse output Set for Forward pulse ou
18. Es 02 External Counter Badger Meter ER8 Common 6 01 or AMR Device External Disconnect ACAUTION Terminal 1 Input 1 Input Functions reset positive zero return Position this device in an accessible location Terminal 2 Output 1 Programmable passive output to Position and identify the disconnect device so as to provide Badger external counter safe and easy operation Functions forward pulse frequency output preset output flow set point error alarm flow direction Label the disconnect device as being for the Mag Meter Active Output to external counter Install an external disconnect switch or circuit breaker that Terminal 3 Output 1 ProgrammableTransistor Output meets local standards open collector Passive Output to Badger external counter Functions forward pulse AMR pulse flow set point error AC Power Wiring alarm empty pipe flow direction For AC power use three wire sheathed cable with cable Active Output to external counter diameter of 18 AWG not supplied Terminal 4 Common field ground AC wire insulation temperature class must not exceed the maximum ambient temperature of its location typical 185 F Terminal 5 Analog Output 85 C Terminal 6 Ground from external counter device connected Use conduit and conduit fittings not supplied that are rated to terminal 5 for Class I Div 1 hazardous locations To maintain a NEMA 4X rating use watertight fittings that are rated NEMA 4X
19. H5D SN OC yovid nue ALIHM qT14IHS LNITVAINOA YO SSL6 NIOT139 11 NOTE Plastic cover must be reattached to maintain hazardous location rating 3 Strip the cable jacket back 2 inches 50mm 4 Strip the 4 wires back 4 inch 6mm 5 Thread wires through the proper cable access Connect the wires to the compression style screw terminals of the Detector Junction Box BELDEN 9155 OR EQUIVALENT ELECTRODE WIRES 18 20 AWG OR 1 0 0 5 mm 2 CLEAR RED SHIELD BELDEN 8770 OR EQUIVALENT SEAL FOR ZONE 1 INSTALLATION CONDUIT SEAL LOCATED AT ENCLOSURE ENTRY PER 505 18 FOR CLASS 1 DIV 1 OR 2 FOLLOW NEC 501 4 AND 501 5 FOR CLASS 1 ZONE 1 FOLLOW NEC 505 15 AND 505 18 Red to terminal labeled El Green to terminal labeled SHLD Black to terminal labeled E2 White to terminal labeled EP Cable length between Junction Boxes may be up to 100 feet 30M 6 Run cable and conduit to Amplifier junction box Electrode Wiring in Amplifier Junction Box To connect the electrode wires in the Amplifier Junction Box 1 Unscrew the amplifier junction box chamber cover If necessary use a strap wrench 2 Remove the protective plastic cover to access the terminal block screws NOTE Plastic cover must be reattached when wiring is complete to maintain hazardous location rating 3 Strip the cable jacket back 2 inches 50mm 4 Strip the 4 wires back 1 4 inch 6mm 5 Thread wires through th
20. M Series Mag Sader habe Installation amp Meter Operation Manual IMPORTANT Read this manual before attempting any handling or installation of the meter IOM 123 03 BadgerMeter Inc 0 J 6JeJ JO 01an 9 10 Disclaimer The user purchaser is expected to read and understand the information provided in this manual follow any listed Safety Precautions and Instructions and keep this manual with the equipment for future reference The information in this manual has been carefully checked and is believed to be entirely reliable and consistent with the product described However no responsibility is assumed for inaccuracies nor does Badger Meter Incorporated assume any liability arising out of the application and use of the equipment described Should the equipment be used in a manner not specified by Badger Meter Incorporated the protection provided by the equipment may be impaired Questions or Service Assistance If you have questions regarding the product or this document contact Badger Meter Incorporated P O Box 245036 Milwaukee WI 53224 9536 Telephone 414 355 0400 877 243 1010 Fax 414 355 7499 866 613 9305 On the Web www badgermeter com or call your local Badger Meter representative Product Identification Information Record the product identification numbers from the nameplate Modular Mag Meter Model Number _M 4000 Serial Number Tag Number if applicabl
21. Menu Press E 17 MAIN MENU 00 returns with the arrow pointing at Exit Ei E 11 After pressing E the menu goes back to ANALOG OUTPUT 31 Press three times to place arrow at FS Calibrate Press E once 12 Screen ANALOG FS CAL 3C comes up Press to set the arrow across from Decrease AO or Increase AO Press E button until amp meter reads the desired Full Scale Set point mA Analog OUT TERMINAL 9 Press to set at Exit WITH save 10 Press E to Save 18 The screen returns to the Main Screen The above programming sequence guided you through various screens and programming These are the basic functions that need to be programmed initially Please refer AMP METER to the programming flow chart located on pages 34 36 for all of the programming options 13 Press to set screen at Exit WITH save 14 Press E to Save 27 DETECTOR SPECIFICATIONS M 4000 Meter Mount Amplifier on Detector M 4000 Remote Mount Junction Box on Detector C with Amplifier GPM LPM inch mm inch mm inch mm inch mm inch mm _ K Min Max 1445 366 35 89 15 15 Lbs Kg Min Max 0 063 1445 366 35 89 1515 38 125 57 008 9 0114 34 3 8 10 Ya 3 4 14 45 366
22. T PT MIN 3F enter a number as described earlier Press E NOTE When the flow rate falls below the minimum setpoint valvue entered as a percentage of full scale the output will activate 2 The Screen returns to DIG OUTPUT 1 33 Press four times then press E 3 In SET PT MAX 3G enter a number as described earlier NOTE When the flow rate exceeds the set point value entered as a percentage of full scale the output will activate This is only for Flow Set Point Refer to page 35 Digital Output 1 OUTPUT TYPE 1 Press or activate the letter E to return to screen DIG OUTPUT 1 33 SWITCHE WM 2 In DIG OUTPUT 1 33 press five times to Output Type 3 In OUTPUT TYPE 3H press Normally Open or Normally Closed e Select N O or N C for any output Refer to page 35 Digital Output 1 QUTPUT TA Exit e Normally Opened or Closed Selected shows for two seconds programmed There are four Digital Outputs in this program Perform the same for all of them if applicable Note that not all output functions are available on all outputs Analog Output e The screen goes back to DIG OUTPUT 1 33 kama 1 Press E once to move cursor to Main Menu 4 Pres six times or once to Select Function 2 Inthe MAIN MENU 00 press three times to move the Seas cursor to Inputs Outputs Next press E 5 When Select Function is selected screen Z1 appears for two seconds 3
23. T1 T2 and PS R Flow Rate T1 registers Forward Volume T2 registers Forward Volume and can be reset through Input 1 LA Hee w trek PS registers Preset Batch Amount With this information an operator can tell at a glance the volume going through the meter Bi Directional Flow Main Screen Bi Directional Flow totalizes pipe flow in both directions reference page 24 Set Flow Direction to program for Bi Directional Flow Bi directional totalizers readings on the display screen are identified as R T T TN and PS Flow Rate T registers Forward Volume T registers Reverse Volume TN Net Total T T PS registers Present Batch Amount 17 With this information an operator can tell at a glance the volume going through the meter in both directions PASSWORD ENTRY With your Main Screen showing on the display switch or press E Screen PASSWORD 01 opens PASSWORD 01 is a typical Input Numbers screen If a password has been entered into your program this screen opens reference page 22 Input a Password for programming a password An underscore _ is positioned under the first 0 1 Switch or press to increase the number by one digit Switch or press to decrease the number by one digit 2 After the correct number is entered for that digit press E to move the underscore to the next 0 3 Repeat the number selection process for this and all the O s 4 A
24. a parameter turn a parameter on or off etc or a screen with another list may open requiring another selection be made to access and set a specific parameter size numeric unit or on off configuration Each screen has a name and number that displays at the top of the screen Write down screen names numbers and parameters that you access and change should other 4 Screen Pipe Dia 11 opens changes be needed later NOTE Your metering requirements may not require the use selection of all screens options and parameters MAIN MENU 00 is a typical List screen It provides access PIPE DIA 11 is a list of pipe diameter sizes to parameter screens The MAIN MENU is a list of eight selections and an Exit this Menu choice All amplifier programming and parameters are accessed from this list 1 Press or to position the arrow at a select selection MAIN MENU Ba Exit this Menu Meter Setur Measurements A 2 For example press once to place the arrow at Meter Setup O m MAIN MENU Be Exit this Menu Heter Setur Measurements SWITCHE FUN 3 Next press E IS 1 5 3 1 3 1 1 2 2 3 4 5 6 8 1 1 N O 5 Press or to position the arrow at the appropriate pipe size 4 Screen METER SETUP 10 opens 19 2 For example place the arrow at Pipe Dia by pressing or PIPE DIA 11 is another List screen It requires a parameter 6 Pre
25. ach chamber cover Adjustable Display Control Card Because meter positioning sometimes places the amplifier display programming chamber in an awkward position the display control card is adjustable in 90 degree increments Disconnect main power to the unit before attempting any device maintenance To re position or rotate the display control card in the amplifier 1 Remove display chamber cover Turn the cover counterclockwise to remove it from the amplifier If necessary use a strap wrench 2 Remove the 2 card screws and washers NOTE Use a split screwdriver to prevent dropping screw into enclosure 15 3 4 5 6 7 Tilt card up out approximately 45 degrees at the holding clips Gently pull card down and out from between holding clips Rotate card to appropriate position Angle card and position card holes between the holding clips Push card in between holding clips Lower card back into position and attach card with screws and washers 8 Attach the chamber cover AMPLIFIER CONTROLS CONTROL METHODS and DATA DISPLAY PROGRAMMING The M 4000 amplifier display programming chamber contains a display control card This card and its display screen provide easy access to meter information and the ability to view program and adjust meter data parameters Display Programming Chamber and Display Control Card Card Display and Controls The M 4000 uses a 2 5 X 1 inch 6
26. ction box Use a NEMA 4X Y inch NPT fitting 6 Install protective plastic cover over terminal blocks 7 Attach detector chamber cover Cable length between Junction Boxes may be up to 100 feet 30M 12 Coil Wiring in Amplifier Junction Box To connect the coil wires in the amplifier junction box 1 Strip the cable jacket back 2 inches 50mm 2 Strip the 2 wires back 4 inch 6mm 3 Connect the wires to the compression style screw terminals of the amplifier junction box FOR ZONE 1 INSTALLATIONS CONDUIT SEAL LOCATED AT ENCLOSURE ENTRY PER 505 18 SEAL BELDEN 8770 EQUIVALENT SHIELD SL COIL WIRES FOLLOW NEC 504 SHIELD BELDEN 9155 OR EQUIVALENT Red to terminal labeled C1 Clear to terminal labeled C2 4 Connect conduit to junction box Use a NEMA 4X Y inch NPT fitting 5 Install protective plastic cover over terminal blocks 6 Attach the amplifier junction box chamber cover OUTPUT WIRING The Badger M 4000 Meter converts liquid flow into electrical signal s With proper output wiring and amplifier programming the signal s are sent to and used by processing equipment used in operations or other procedures NOTE Output wires and terminals are the same for meter mount or remote mount meters Output wiring requires 18 to 22 AWG maximum shielded wire not supplied Signal wire insulation temperature class should exceed the maximum temperature where installed typ
27. e TABLE OF CONTENTS DISCIAMMON ii ninia 2 QUESTIONS OF SEFVICE ASSIM CO o AiO einer isis 2 Produectidentificaton IO MAIN da wu nu DS usu aaa Oraa aE aAA a 2 SAFETY PRECAUTIONS and INSTRUCTIONS oia A aca 4 Equipment Unpacking Inspection Moving and Return Policies rr 4 Rigging biting MOVNO Large NS idol 4 Instructions Specific to Hazardous Area Installations uu u u u 5 METER DESCRIPTION cuota io aiii cabana 6 EMPIARIDO DEC A ei bi a say 6 AMDIMEEM CUARTA OPINAS A e a a Sl 6 Mete MOE naaa 6 A A NO 6 METER AMPLIFIER LOCATION ORIENTATION and APPLICATIONS 6 Herriote AmpliierOorildooE E6Call g ak e aa hana umuy ama Sal 6 Jeni PAULIN ea O A asap aaah 6 FID CHIME SHG FUJ lOW au uuu O a usss aaa aaa 7 METROS A e eo ree o aus 7 VoiliCalipi G ne dad tee a a E a Gane eet inee antenna natu 7 MORzZontal Flaco menta ins ice 7 SthalQhit Pipe ACEQUIA sos e e 7 Pipe Reducer Regdirement oi A ir NS usuka uuu a uuu 7 Chemical IMectlonAPpPlICA ON S sea a A a o o usu a Qu apup ere at 8 partially Filg Pipe Situations A O a canted Neer 8 Meter Gaskets and Grounding ice ise u O e cial 9 METER INS TAT PIO IN usina o Us 9 Remote MOUnNTAMPINE secession us ad se cae ayat A gi A ok DO O 10 Remote Mount Amplifier Detector Wi
28. e proper cable access Connect the wires to the compression style screw terminals of the Amplifier Junction Box FOR ZONE 1 INSTALLATIONS CONDUIT SEAL LOCATED AT ENCLOSURE ENTRY PER 505 18 SEAL BELDEN 8770 EQUIVALENT FOLLOW NEC 504 SHIELD ELECTRODE WIRES BELDEN 9155 OR EQUIVALENT Red to terminal labeled El Green to terminal labeled SHLD Black to terminal labeled E2 White to terminal labeled EP Coil Wiring in Detector Chamber To connect coil wires in the Detector chamber 1 Lay out the cable and conduit between the Detector Junction Box and the Amplifier Junction Box Use Belden 8770 cable or equivalent for coils NOTE Plastic cover must be reattached to maintain hazardous location rating 2 Strip the cable jacket back 2 inches 50mm 3 Strip the 2 wires back 1 4 inch 6mm 4 Thread wires through the proper cable access Connect the wires to the compression style screw terminals of the detector chamber BELDEN 9155 OR EQUIVALENT SHIELD WHITE 18 AWG BLACK 20 AWG GREEN 18 AWG RED 20 AWG 18 20 AWG OR 1 0 0 5 mm 2 COIL WIRES 3 SHIELD al BELDEN 8770 EQUIVALENT SEAL FOR ZONE 1 INSTALLATION CONDUIT SEAL LOCATED AT ENCLOSURE ENTRY PER 505 18 C FOR CLASS 1 DIV 1 OR 2 FOLLOW NEC 501 4 AND 501 5 FOR CLASS 1 ZONE 1 FOLLOW NEC 505 15 AND 505 18 to terminal labeled C1 Clear to terminal labeled C2 5 Connect conduit to jun
29. e range surrounding the junction box must not exceed 122 F 50 C 4 During any installation or repair perform all procedures in accordance with the applicable code of practice 5 Suitably trained personnel shall perform all installation or repair procedures 6 Ifthe equipment is likely to come into contact with aggressive substances it is the responsibility of the user to take suitable precautions that prevent it from being adversely affected thus ensuring that the type of protection is not compromised Aggressive Substances e g acidic liquids or gases that may attack metals or solvents that may affect polymeric materials Suitable Precautions e g regular checks as part of routine inspections or establishing from the material s data sheet that it is resistant to specific chemicals Additional Information Certification markings are noted on the product label Markings include _M SERIES MAG METER Model 4000 i Serial gt APPROVED PERENE o Badger Meter Brno Czech Republic Power 85 240 VAC 50 60 Hz 15VA Type 4X IP66 CLI Divi GP BCD T4 S CLII Divi GP EFG T4 A Exia Provides intrinsically safe electrode circuits Warning Substitution of components may impair Intrinsic Safety 20 C Tamb 50 C D uc H O O ee eee ee ee 7 7 7 7 For additional information regarding importation equipment installation equipment repair equipment return or rene
30. e shipping container for unpacking lifting or moving instructions 3 As the unit is opened and unpacked verify the shipment packing list and your order form match the items in the shipment 4 Open the container and remove all cushioning materials Keep the shipping container and packing materials should the meter need to be returned or put in storage 5 Remove the meter from the container For meter flow tube diameters between 2 and 8 50 and 200mm use a crane or lifting device with soft straps placed around the detector body at the flanges For meter flow tube diameter sizes 10 250mm and larger lift the unit via the lifting lugs with a crane cables and hooks 6 Inspect the meter for signs of shipping damage scratches loose or broken parts NOTE If damage is found a formal claim for damage in transit is the responsibility of the customer Within 48 hours of delivery request an inspection report from the carrier File a Claim with the carrier Contact the Badger Meter factory to facilitate repair or replacement 877 248 1010 7 All detectors with PTFE liners are shipped with a liner protector to maintain proper form of the PTFE material during shipping and storage NOTE Do not remove the liner protector until installation 8 Storage If the meter is to be stored place it in its Original container in a dry sheltered location Storage temperature ranges are 4 F to 158 F 20 C to 70 C Rigging Liftin
31. ed Due to continuous research product improvements and enhancements Badger Meter reserves the right to change product or system specifications without notice except to the extent an outstanding contractual obligation exists BadgerMeter Inc P O Box 245036 Milwaukee WI 53224 9536 Telephone 414 355 0400 800 456 5023 Fax 414 355 7499 866 613 9305 www badgermeter com
32. f screen shows for 2 seconds when arrow Press E Damping Factor time is selected Set Flow Direction 5 MEASUREMENTS 20 screen returns with the arrow 1 At MEASUREMENTS 20 press five times to set the pointing at Exit this Menu EX BIOS 6 Press E once to place cursor at Main Menu 00 2 AtFLOW DIR 25 press or to select Uni Directional or oo 7 Press E once to move cursor back to the Main Screen 3 This type of screen shows for 2 seconds Set Damping Factor Empty Pipe Calibration 1 At MEASUREMENTS 20 press six times to move the arrow to Damping Factor Press E Press E once to move to Main Menu 2 At DampingFactor 26 press Exit this Menu No Damping 2 Inthe MAIN MENU 00 select to Meter Setup or press a Time Frame 3 If No Damping is selected this type of screen shows for 2 seconds 3 In METER SETUP 10 select Empty Pipe 23 In EMPTY PIPE 15 select Cal empty pipe Select Cal OFF E ON press or select E once to change OFF to ON NOTE Make sure the Flow Detector Pipe is Empty NOTE With the pipe empty the usage reading should be between 3 00 and 3 30 Volts Select Exit WITH save Press E once to save the setting and return to EMPTY PIPE 15 In EMPTY PIPE 15 select at Cal full pipe Then press E Select Cal OFF E ON press or select E once to change to OFF to ON NOTE Make sure the Flow Detector pipe is full of fluid NOTE The full
33. fter the last number is entered press E 5 The MAIN MENU appears However if the wrong password was entered Screen INVALID PSWD 02 opens 1 Select or E to return to the Main Screen 2 Press E again 3 The screen returns to PASSWORD 01 Enter the correct password as described above All passwords are factory set to 0000 no password is programmed or required If 0000 is the password pressing E from the Main Screen opens the MAIN MENU screen Amplifier Access Switches Buttons Accessing amplifier menus movement to and between screens parameter selections and settings are all accomplished by pressing the and E magnet operated switches or push buttons in conjunction with an on screen location arrow o Continue selecting E to return to the Main Screen we y If your amplifier is not password protected pressing E from the Main Screen accesses the MAIN MENU 7 47 MAGNET OPERATED SW ITCHE The MAIN MENU is a list that provides access to all amplifier menus and parameters If your amplifier is password protected and E is pressed from the Main Screen the PASSWORD screen opens reference PASSWORD 01 below Ai How to Program Amplifier screens menus and program parameters are arranged in the familiar branching format where the MAIN MENU screen is a list of selections The Main Menu list provides access to other lists selections or parameter screens which provide input for
34. g Moving Large Units DO NOT lift or move a meter via its amplifier junction box or cables Lift and move meters with flow tubes between 2 and 8 50 and 200mm with a crane rigged with soft straps Place a strap around the detector body between the flanges on each side of the detector E 3 Lift meter flow tube diameter sizes 10 250mm and larger via its lifting lugs Use the proper size crane cables and hooks DO NOT lift the meter by the amplifier or on remote style meter by the junction box Use the sling rigged method to lift large detectors into a vertical position while still crated Use this method to position large detectors vertically into pipelines Do not lift a detector with a forklift via the detector body between the flanges The housing could be dented and or damage caused to internal coil assemblies NEVER place forklift forks or rigging chains straps slings hooks or other objects inside or through the detector flow tube for lifting or handling purposes The isolating liner could be damaged rendering the unit inoperable Instructions Specific to Hazardous Area Installations These instructions apply to equipment covered by FM Certificate Number 3015930 1 The temperature range for fluids passing through the detector is 4 F to 248 F 20 C to 120 C 2 The ambient temperature range surrounding the amplifier is 4 F to 122 F 20 C to 50 C 3 The ambient temperatur
35. h bracket to amplifier with supplied screws Torque screws to 80 in lb Mount Bracket Amplifier to Location 1 Position the bracket amplifier in the desired orientation 2 Secure bracket amplifier to location REMOTE MOUNT AMPLIFIER DETECTOR WIRING Remote Mount Amplifier The remote mount amplifier has three chambers and five wire ports The Junction Box and Connections Chambers and wiring ports provide amplifier openings for wire conduit tool and hand access to amplifier terminal blocks Detector to amplifier wires connect in the Junction Box Chamber Amplifier AC power and customer signal wires attach in the Connections Chamber The Display Programming Chamber provides access to fuses and circuit boards They are discussed later AC Wires Port Customer Signal Wires Port Connections Chamber Display Programming Chamber Junction Box A Chamber Electrode Wires Port Wires Port REMOTE MOUNT AMPLIFIER Refer to the Remote Mount Wiring Diagram on page 11 Detector Junction Box The Detector Junction Box has one chamber and two wire ports The junction box chamber and wiring ports provide openings for wire conduit tool and hand access to terminal blocks Detector to remote mount amplifier electrode and coil wires connect to the detector through the chamber wire ports 10 Coil Wire Port Electrode Wire Port Chamber D gt Mw DETECTOR JUNCTION BOX Suitably trained
36. ical 185 F 85 C Use conduit and conduit fittings not supplied rated for Class Div 1 hazardous locations Output Wire Connections Properly trained personnel must perform all installation and or repair procedures Disconnect power to the unit before attempting any installation or maintenance 13 To connect control signal wires 1 Remove the connections chamber cover If necessary use a strap wrench Remove the two terminal block wire port access screws Connect output wires to processing equipment 4 Group and place output wires in conduit Position conduit at amplifier terminal block wire ports Connect conduit to control output signal wires ports 6 Run output wires through wire ports into amplifier terminal chamber 7 Strip output wires back inch 6mm 8 Connect output wires to terminals see below w N a NOTE Use twisted pair shielded wire for all output wiring Belden 1266A or equivalent Amplifier Output Wire Terminal Block Connections Reference Control Signal Wiring Diagrams on next two pages Customer Connection Wiring Diagram Class 1 Div 1 Badger Meter Inc INPUT 1 OUTPUT 1 OUTPUT 2 COMMON 420mA SOURCE COMMON e Output 2 Functions Reverse only Pulse Transistor Output open collector Frequency Output 24VDC Max Preset Output Programmable 5W Max Flow Set Point Error Alarm Flow Direction Passive Output Output 2 5
37. ion the cursor at Empty Pipe 5 Select or press E 6 Screen Empty Pipe 15 opens Empty Pipe 15 is a typical select ON OFF screen Empty Pipe is usually shipped OFF To turn Empty Pipe On 1 Press once to move the cursor down one place to Cal empty pipe 2 Press E In screen EMPTY CALIB 1E press twice Press E to turn Cal ON ie 5 Press to move cursor to Exit WITH save 6 Press E to lock the selection into the program Continue pressing E to reverse through the screens to your next programming selection or to return to the Main 21 Screen You have now used the and E selections to access the three types programming screens List Input Numbers and Select ON or Off and maneuver through some meter programming What to Program There are a variety of screens available Refer to the Flow Chart Menu Structure on page 35 for all programming options PROGRAMMING REQUIRED PARAMETERS All meters have required parameters that must be programmed They include a Password if desired the Main Screen for Uni or Bi Directional Flow Empty Pipe Pulse Output and Analog Output among others This section presents keystroke details describing how to program required parameters Input a Password 1 With Main Screen up press E to open MAIN MENU 00 2 With MAIN MENU 00 up press once to move cursor to Meter Setup Press E 3 On METER SETUP 10 screen press six times or
38. mizes installation wiring Meter Mount Remote Mount Configuration Remote Mount configuration places the amplifier and its functions at a location separate from the fluid flow and detector This configuration is necessary in situations where process fluid temperature or environment exceeds amplifier ratings A remote mounting bracket is supplied Detector and amplifier are connected by wires run through conduit between junction boxes on the detector and remote mounted amplifier The distance between the detector junction box and amplifier junction box can be up to 100 feet 30m This configuration can also provide a more convenient amplifier programming and display placement for monitoring meter readings Junction Box on Detector Junction Box with Remote Amplifier METER AMPLIFIER LOCATION ORIENTATION and APPLICATIONS Remote Amplifier Outdoor Location The amplifier can be installed and operated outdoors However protection from the elements must be considered 1 Be aware of the ambient environment and temperature ratings for the unit 4 F to 122 F 20 C to 50 C 2 If an indoor location is within 100 feet 30m of the detector installation consider increasing the cable length and mounting the amplifier indoors 3 Ata minimum fabricate a roof or shield over and or around the amplifier to protect the LCD display screen from sunlight Temperature To prevent meter damage in any environment minimum a
39. nce or cleaning Do not clean components inside the amplifier or junction box Flow Tube and Electrode Cleaning At times flow tube electrodes amplifier junction box housings and the amplifier window may need periodic cleaning depending on process fluid properties fluid flow rate and surrounding environment Clean the flow tube and electrodes by following the material handling and cleaning procedures documented in MSD Sheets for the products s that were in contact with the flow tube and electrodes Should flow tube and or electrode cleaning become necessary Disconnect detector from pipeline N Clean electrodes with isopropyl alcohol or fresh clean water depending on the chemical compatibility of the measured fluid 3 Reconnect detector to pipeline Fuse Replacement AWARNING Disconnect main power to the unit before attempting any device maintenance Risk of electrical shock Replace fuse ONLY with the same type and rating Authorized personnel must perform fuse replacements Replace fuses with fuses of the same ampere rating and type Refer to wiring diagrams when ampere ratings are unknown or questionable Detector coil and incoming amplifier power supplies are each protected by a fuse in the amplifier 30 Detector coils are protected by a 680mA 250VAC slow blow fuse part number 65621 001 Incoming amplifier power is protected by a 500mA 250VAC slow blow fuse part number 65621 002
40. nd maximum temperature ranges must be observed 1 For remote amplifier applications the fluid temperature range is 4 F to 248 F 20 C to 120 C at a maximum ambient temperature of 122 F 50 C for the following liner materials PFA and PTFE 2 For remote amplifier applications the fluid temperature range is 32 F to 178 F 0 C to 80 C at a maximum ambient temperature of 122 F 50 C for the following liner materials Hard rubber and soft rubber 3 For meter mounted amplifier applications the fluid temperature range is 4 F to 212 20 C to 100 C ata maximum ambient temperature of 122 F 50 C for the following liner materials PFA and PTFE 4 For meter mounted amplifier applications the fluid temperature range is 32 F to 178 F 0 C to 80 C ata maximum ambient temperature of 122 F 50 C for the following liner materials Hard rubber and soft rubber 5 The ambient temperature range surrounding the amplifier is 4 F to 122 F 20 C to 50 C 6 The ambient temperature range surrounding a remote junction box mounted to the detector is 4 F to 248 F 20 C to 120 C Pipelines and Fluid Flow Pipeline and fluid flow conditions that should be avoided 1 Do not install the meter where extreme pipe vibrations exist If vibrations are present secure piping before and after the meter with appropriate pipe supports If vibrations can t be restrained consider mounting the amplifier remotely 2
41. or velocities less than 1 64 ft s 0 50 m s Repeatability 0 1 of rate Flow Range 0 10 to 39 4 ft s 0 03 to 12 m s Fluid Conductivity Min 5 0 micromhos cm Flow Direction Unidirectional or bidirectional programmable Totalization 3 separate displayable totalizers 10 digits programmable forward reverse and net Analog Outputs 0 10mA 0 20mA 4 20mA programmable and scalable Voltage sourced 18VDC isolated Max loop resistance 750 O Frequency Output Open Collector Max full scale flow 10Khz Digital Outputs 2 Open collector programmable scaled pulse flow alarm status or frequency output Max 24VDC 0 5W 2 AC solid state relay programmable flow alarm or status Max 24VDC 0 5A Pulse Width Open collector 5ms to 1 second programmable or automatic 50 duty cycle Min Max Flow Alarm Open collector or solid state relay programmable 0 to 100 of flow Empty Pipe Detection Field tunable for optimum performance based on specific application Excitation Frequency Programmable 3 75Hz 7 5Hz or 15Hz 29 Junction Box on Detector Junction Box on Amplifier Auxiliary Input Max 24VDC programmable positive zero return external totalizer reset or preset batch start Noise Dampening 1 to 30 seconds programmable Units of Measure U S gallons imperial gallons million gallons per day cubic feet cubic meters liters oil barrels pounds ounces acre feet Low Flo
42. parameter settings for each select press MAIN MENU Move the parameter numeric setting underscore The MAIN MENU contains a list of eight selections and _ one place to the right for each select press an Exit this Menu choice All amplifier programming and when inputting parameter numeric settings parameters are accessed from this list SAVE a parameter numeric setting After all numbers are input press E and the setting is saved the screen closes and the previous screen with the arrow pointing at Exit this Menu shows again Select E again That screen closes and the previous screen appears with the arrow pointing at its Exit this Menu 18 MA N ME N U 0 0 METER SETUP 10 is another List screen It provides access to common meter parameters gt Exit this Menu 1 Maneuver the or magnetic switches or push buttons Me t er S e t u p to position the arrow at a Clete Measurements I nputs Outputs Clear Totals Communi cations I nfo Help Logout activating button once METER SETUP Only four lines of text are visible on the display screen 4 hh Operating the and switches buttons moves text up or eee Di a Me a down and into view Detect When an item from the list on the MAIN MENU is selected press E when the item is in line with the arrow either a 3 Press E to open the Pipe Dia screen screen opens that requires an action such as select a size or numeric unit for
43. personnel shall perform all installation or repair procedures Disconnect power to the unit before attempting any installation or maintenance Do not bundle or route signal wires with power wires Use proper conduit connections and supplied cables in all wiring procedures Observe all local applicable electrical codes when wiring any equipment Electrode and Coil Wiring From Detector Junction Box to Remote Mount Amplifier Junction Box A remote mount unit requires electrode and coil cables from the detector junction box to the amplifier junction box be enclosed in properly rated conduit Use conduit fittings not supplied that are rated for Class I Div 1 hazardous locations Failure to use proper conduit fittings rated for Class I Div 1 hazardous locations invalidates the FM rating and any warranties expressed or implied for this equipment 1 Lay out the cable and conduit between the Detector Junction Box and the Amplifier Junction Box Use Belden 9155 cable or equivalent for electrodes Use Belden 8770 cable or equivalent for coils 2 Run cables through the conduit between Detector Junction Box and Amplifier Junction Box 3 Place four Nema 4X 1 2 inch NPT fittings on conduit 4 Remove the four junction box wire port screws two on each junction box Electrode Wiring in Detector Junction Box To connect electrode wires in the Detector Junction Box 1 Unscrew the Detector chamber cover If necessary use a strap
44. ration the mag meter impact ground zero voltage reference must be connected to the liquid media and to a good solid earth ground Perform grounding procedures after the meter is connected to the pipeline Conductive Pipe Grounding A grounding bolt is located on each mag meter flange Drill and tap the pipeline flanges on each side of the meter and install a grounding bolt to each To ground the unit attach a ground strap provided of copper wire at least 12AWG size between the grounding bolts on the meter flanges and the bolts on the pipeline flanges Do this on the inlet and outlet sides of the meter Non Conductive Pipe Grounding If the process pipeline material is not electrically conductive and your meter was not ordered with an optional grounding electrode place a grounding ring available from Badger Meter between two gaskets on both ends of the meter GROUNDING RING INSTALLATION KIT SUPPLIED HARDWARE INCLUDES 2 GROUNDING RINGS 4 BOLTS 4 LOCK WASHERS 2 NUTS 2 GROUND STRAPS qam aa After the grounding rings gaskets and meter are assembled to the pipeline attach ground straps provided of copper wire at least 12AWG size to grounding bolts on meter flanges and to the grounding rings If your meter was ordered with an optional grounding electrode the use of grounding rings is not necessary METER INSTALLATION PLANS and EXECUTION Plan meter layout location and installation During
45. ring cc cccccccsseceecceeeeecceusseeeceaeeeceeusececscaueeceseaseeeensaeeeecsadseeessuaeeeesseeeesesageeeessaseeessaaseees 10 Detector Junction DO e idas 10 Remote Mount Wing DIAM a id id ias 11 Electrode and Coil Wiring from Detector Junction Box to Remote Mount Amplifier Junction Box 12 PIO CHOCO MITO Di e idas 12 A A A A aqe asas ae 12 A o II rant ee amutu h usu nee sas ase 13 EXE ran CONE Cl e clics 15 AG PONG NV URN ee O 15 Adjustable Display CONUSPO OI iy u o uuu usu a ae 15 AMPLIFIER CONTROLS CONTROL METHODS AND DATA DISPLAY PROGRANMIMING 16 Card Display ant CONTOS e asas A as ap Z s e 16 WO PIO AMM MEMOS sra A p Sau ug u aa aE ss O A a 17 MANS e a o e o e Cee 17 E ES LO do DO PARO PRO EE RN s aan 18 AMPIMEtACCeSs SWIlCNeS BUIN ES 18 A o uama au uu agua a atom sa an SD h awakuy asan a a aaa ana 19 A E O OS 22 PROGRAMMING REQUIRED PARAMETERS u u e 22 MPU O A O san asad 22 SA ee ste a r ttn aaah a ae uma er ne ed 23 Cl UNIS CAG OW sts uuu A ec A ore Be au ann NO ig an aad 23 SLOW LOW CUO yuy 2 oa asthe a ls uuu eee O ad 23 A DIECON A earns aspa sup aA arte ee au can ee NO aig ty an a 24 9 Bligoo A bet conten were tt a Cc a ADD Oar uh ee eee een ree ee re 24 EMPOY Pipe Gala O eee nee els 24 ise OTE 01 meee mous ene a O mer arene ae er ae 25 ANOTOU m a uu na uuu ce eae dicate ect atonal nari et cate h unn 2 teen ate
46. ss E SWITCHES B 7 A screen with the statement xx mm xx SELECTED appears for about 2 seconds It verifies that the selected pipe diameter size parameter was entered into the amplifier settings 8 The screen automatically returns to METER SETUP 10 with the arrow pointed at Exit this Menu Transitions 1 Press or to position the arrow at another selection or E to return to the Main Menu MAGNET OPERATED SWITCHE San J al 1 3 Next press three times to position arrow at Inputs Outputs 4 Press E 5 Press three times to position arrow at Digital Out 1 on screen In Outputs 30 6 Press E 8 Press or activate E Pulses Unit 3D is a typical Input Numbers screen 1 When the screen opens the arrow is pointing at a number 2 Use or selections to increase or decrease the underscored number to the desired digit 3 Select E to move the underscore to the next digit and repeat the number selection process 4 To skip a digit press E The underscore moves to the next digit 5 When all digits are set press E Pulses Unit 3D is programmed into the system and the screen Dig Output 1 33 returns Empty Pipe is a branch list screen from the MAIN MENU From here calibrate ON or OFF is made 1 Press E to activate the Main Menu 00 screen 3 Press E to bring up Meter Setup 10 screen 4 Press five times to posit
47. ted Reducers 15 Degree Slope Angle D Pipe Size Standard Concentric Reducers No Distance Required Chemical Injection Applications For water line applications with a chemical injection point install the meter upstream of the injection point This CHEMICAL M 4000 Flow Meter INJECTION HERE UPSTREAM DOWNSTREAM If a meter must be installed downstream of a chemical injection connection the recommended distance between the meter and the injection point must be significant 50 to 100 feet 15 to 30 meters When the water chemical solution reaches the meter it must be a complete homogeneous mixture If the injection point is too close the meter senses two 2 different liquids conductivity is different for each and correct data output cannot be assured The injection method spaced bursts continuous stream of drips a liquid or gas can also affect downstream readings by the meter CHEMICAL M 4000 FLOW INJEC TION METER HERE 50 TO 100 A FEET ARD FLOW FORW 7 vs UPSTREAM DOWNSTREAM Sometimes it s difficult to specify the exact downstream placement distances because of the number of variables Contact Badger Meter Technical Support 877 243 1010 to review your application if necessary Partially Filled Pipe Situations It is possible to encounter situations where the process pipe is momentarily only partially filled Examples include lack of backpressure insufficient line pressure
48. tor to piping with the flow measuring electrode axis in a horizontal plane 3 and 9 o clock This arrangement prevents solids build up or sediment deposit or accumulation on the electrodes Electrode Plane Electrode Plane RIGHT WRONG Straight Pipe Requirements Sufficient straight pipe runs are required at the detector inlet and outlet for optimum meter accuracy and performance An equivalent of three 3 diameters of straight pipe is required on the inlet upstream side Two 2 diameters are required on the outlet downstream side M 4000 Mag FLOWMETER D Pipe Size D Pipe Size ELBOW TEE GATE VALVE 3xD FULLY OPEN MINIMUM STRAIGHT PIPE CHECK VALVE GLOBE VALVE oe BUTTERFLY VALVE x PUMP MINIMUM STRAIGHT PIPE REDUCERS STANDARD CONCENTRIC NO DISTANCE REQUIRED MINIMUM STRAIGHT PIPE ELBOW TEE ANY VALVE MINIMUM PIPING REQUIREMENT Pipe Reducer Requirements With pipe reducers a smaller size meter can be mounted in larger pipelines This arrangement may increase low flow accuracy There are no special requirements for standard concentric pipe reducers Custom fabricated pipe reducers must have an approximate slope angle of 15 degrees to minimize flow disturbances and excessive loss of head If this is not possible install the custom pipe reducers as if they were fittings and install the air cca AM gt cs A AA A TA ARAS lk M 4000 Flow Meter Custom Fabrica
49. tput Set for Flow Set Point output Set for Flow Set Point output Select N O or N C for any output function Forward flow pulse output AMR Forward flow pulse for AMR devices Output will open or close based on set points Output will open or close during error conditions EmptyPipe Error Output will open or close when the pipe is empty Flow Direction Output will open or close when flow direction changes Set for Reverse pulse output Open collector Set for Reverse pulse output Transistor Set for Frequency output Full scale Hz Set batch amount for Preset Output Set for Flow Set Point output Set point max Set for Flow Set Point output Select N O or N C for any output function everse Pulse req Output Reverse flow pulse output Frequency out is proportional to rate of flow Output will open or close when preset amount is reached low Set Point Output will open or close based on set points rror Alarm Output will open or close during error conditions mptyPipe Error Output will open or close when the pipe is empty low Direction Output will open or close when flow direction changes i Set batch amount for Preset Output Digital Out 3 Solid state relay Set for Flow Set Point output Set for Flow Set Point output Select N O or N C for any output function Preset Output Output will open or close when preset amount is reached Flow Set Point Output will open or
50. w Cut Off 0 to 100 of full scale programmable Zero Point Stability Automatic correction LC Display 4 lines X 16 character alphanumeric back light actively displays 3 totalizer values flow rate alarm status output status error diagnostic messages Programming Internal 3 button or external magnetic wand Galvanic Separation 500 volts Electrical Classification FM approved for Class I Div Groups B D Class Il Div 2 Groups E F and G CSA Certified Housing Amplifier enclosure and remote junction enclosure cast aluminum powder coated paint Housing Rating Amplifier enclosure and remote junction enclosure NEMA 4X IP66 Mounting Direct detector mount or remote wall mount bracket included for remote mount max cable distance 100 ft 30M Field Wiring Entry Ports 3 12 NPT internal thread Ambient Temperature 20 F to 122 F 29 C to 50 C Communication RS232C serial standard ANSI terminal compatible data stream MAINTENANCE Mandatory routine or scheduled maintenance should not be required for the Badger M 4000 Mag Meter electronics or flow tube after proper installation However some occurrences may require personnel to perform the following Flow Tube and Electrode Cleaning Fuse Replacement Amplifier I amp C Card Stack Replacement These maintenance procedures are discussed in this section Disconnect main power to the unit before attempting any device maintena
51. wal parts please contact Badger Meter Incorporated P O Box 245036 Milwaukee WI 53222 Telephone 414 355 0400 Fax 414 355 7499 On the WEB www badgermeter com or contact your local Badger Meter representative METER DESCRIPTION Badger Model M 4000 electromagnetic meters are FM approved for Class l Div 1 hazardous locations To achieve hazardous location ratings electrodes in the flow tube are Intrinsically Safe designed according to Factory Mutual FM standards Those standards limit the amount of energy that can be sent to electrodes to prevent a spark from occurring Empty Pipe Detection Badger Model M 4000 Mag meters are equipped with an Empty Pipe Detection feature Empty Pipe Detection is accomplished by positioning a third electrode close to the 12 o clock position Any time this electrode is not covered by fluid for a minimum of five seconds the meter displays an Empty Pipe Detection condition sends out an error message if desired and stops measuring to maintain accuracy When the electrode is again covered with fluid the error message disappears and the meter continues measuring Amplifier Mounting Configuration Options Two amplifier mounting configuration options are available to meet a variety of meter placement and environmental conditions Meter Mount Configuration The Meter Mount configuration has the amplifier mounted directly on the detector This compact self contained configuration mini
52. wrench 2 Remove the protective plastic cover to access the terminal block screws 1INT1VAINO3 YO SSL6 NAG149 v0S DAN AO11O4 qT3IHS ZAA L SSVID HO LAIA L SSW1D YO4 is S tt j as EM YV4A1D qaq q1alHS LNAIVAINOA yO 0228 N30138 Was Twas LINGNOD ANY SNIS OH NJIMI XVNW 8L dau gt y4v315 qT13IHS N m u O L INOZ L AIA L SSW1D IWVd5VIG SNIdIAA LNNOW ALOWSd SIVWNIWYAL GACTAIHS 4LOANNOD OL d3dWn AAY vy TWNIWYAL WHO L 033DX3 LON NYD d3ldl1dIWV JHL OL YOLDSLAG JHL WOY4 NOILLDANNOD GNNOUD JHL 40 JDNVLSISSY IWLOL AHL ALON ALINGNOD 1VLAW AI9IY YO ALINGNOD IWLAW ALVIGAWYALNI qaq avq qTalHS ONISNOH JHL la a o NMOYg 1 F Was OMV 8L z Ww S 0 0 L YO DMY 07 81 S LOS ANY JO WOL109 3HL t LOS DAN MOTIO4 SNOW SIM NNY ALON TYO L AIC L SSV1D YO4 anig gt Was LINGNOD ANY ONISNOH N33M138 XVW 8L esa O S 300419313 MVE 1SOd GNNOYD 300419313 1NOy4 3S5NV 14 WYJYLSNMOQA FALL PI D 4109 SQTAIHS 00 M STSOS DIN NOILDSNNOD ONNOYO HL8v3a SONILDALOYd AJOINOYA YAWOLSND MOTIHA N3389 qTHS AS AS 3A331S ANId di 110D WOY3 3A3315 qatu 343315 32V18 za qTHS 3A331S JLIHM 13 109 WOY3 3133158 3Ma eee eee eee ee eee ee 2 r 39IH NI DMId I LNATWAINOA yO 0228 N3139 qTa3IHS Y4v319 DMY 07 adgy DMY 8L N33

Badger M4000 Magmeter Manual

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