User Manual - Controls Warehouse
Contents
1. 19 Using the M5000 Main Menu Programming 20 Display Menu Screen Hierarchy Structure 6 hh hh s 20 21 Setting a Pr 21 Logging Mss c GE RUE ARR A ROE A RR CARR AD NOR ADR RC UE EMRE ARSED ERE COR a ERR 21 Logging Out cur eee aie ata eh aL RE a eed Mok aa a a Be Od Badal e Gee eee os a 21 Meter Setup roci dd ce ache te cea De axa Cah ada te NOR RO RH RON 22 Measure i ose a tate tse GG Be Ao os ore ww ee 23 Inputs Outputs Men s xu RULES RUN R UR Re AL RO RUE ha we ah ee Re Oe 25 Communication eds oa RR OR OR era EUR UR RON o ka ee ee a ee ae 27 Miscellaneous Menu auae Ra e cea hae 28 Information MENU seseante aenea ERAS 28 AED TITULI 29 Faults act aa 29 Maintenance assu RU X E ER KG NO A ER X E ER RS RA AUR UR ERROR REDE RARE 30 Cleaning the Flow Tube and 0 30 Troubleshoot2. Blank display Dead battery Replace battery Flow rate value Detector factor Check value on label known to be wrong Deposits on electrodes and or liner Check and remove deposits Incorrect pipe size programmed Check size if necessary Flow rate indication Cable issue Make sure cable is shielded and not vibrating unstable Grounding issue Make sure meter is properly grounded to a good earth ground Partially full pipe Make sure pipe is full of fluid Air in pipe Make sure fluid does not contain air bubbles Invalid fluid conductivity Make sure amplifier is not too close to sources of electrical interference August 2014 MAG UM 00219 EN 04 Page 31 Troubleshooting Errors amp Warnings What You See Why It Happened How to Fix It MEASURE_TIMEOUT The board may be damaged Contact Badger Meter Technical Support COMMON_MODE_VOLTAGE_ OVERLOAD Common mode voltage is smaller than 2 0 or larger than 4 1V Make sure the meter is properly grounded Empty detector Switch Empty Pipe detection ON Dirty electrodes Clean the electrodes EMPTY PIPE WARNING Measured impedance between the Empty Pipe electrode and the Ground exceeded the set value Empty detector Make sure the pipe is filled Check Empty Pipe threshold It should be 60000 corresponds with 20 uS cm PULSE OVERLOAD WARNING Overflow occurred on the flow output Low
3. 10 Chemical Injection 55 255 5 86 444644444 RO OE eee 10 Partially Filled Pipe Situations 5 ERA EG ey Geel E OR UR XU A HUE RR ED 11 Meter Gaskets and Grounding se caas seria RR a OR Ewe OR COUR ORO ROO OR CORR OR RR a 12 Meter Pipeline Connection 5 12 Meter Gro nding esee once er ee a qr doa Qe qoa Re gest a Qe qos uh ee 62 12 Conductive Pipe Grounding 2 camp c ERR XR X E X XE nee ho ee REC GR EG XL RUE E XC 12 Non Cond ctive Pipe Grounding ss 414 ap ois s UR RR ACH AUN ONUS CERA we OS 12 Amplifier Mounting Configuration Options 2 6 he 13 Meter Mount Configurations sess aen o eR UR a SOROR GE OE ONE ORA So RON ey OR ORO 13 Remote Mount Configuration 49s pep tebe E X EAE XR E XE YEA 13 Submersible Option c ate i ok due UR d ee dee dedo feo d 13 Wiring zz doc ERG REG GREY SEGUE Ed ROUGE ROC QUE E RAE RES UR TEES ew E PUR Rd 13 Wiring Safety sucer shea ees OEE EE ee os od Rao e 13 Opening the M5000 Covel ue UR ae eR RR UR EX ARR AS eee es 13 oru m TT 14 Battery as sm paene XE ahaa Ce whee aue US SCR I 14
4. Do not remove the liner protectors until you are ready to install Storage If the meter is to be stored place it in its original container in a dry sheltered location Storage temperature ranges are 40 160 F 40 70 C Rigging Lifting and Moving Large Units WHEN RIGGING LIFTING OR MOVING LARGE UNITS FOLLOW THESE GUIDELINES Page 6 DO NOT lift or move a meter by its amplifier junction box or cables Use a crane rigged with soft straps to lift and move meters with flow tubes that are between two inches and eight inches 50 mm and 200 mm Place the straps around the detector body between the flanges on each side of the detector Use the lifting lugs when lifting meter flow tubes that are 10 inches 250 mm in diameter or larger Place straps between flanges Use lifting lugs with 10 inch or larger meters Figure 2 Rigging Large Units MAG UM 00219 EN 04 August 2014 Unpacking and inspection Usethe sling rigged method to lift large detectors into a vertical position while they are still crated Use this method to position while they are still crated Use this method to position large detectors vertically into pipelines Figure 3 Sling Rigged Lifting Methods Do not lift a detector with a forklift by positioning the detector body on the forks with the flanges extending beyond the lift This could dent the housing or damage the internal coil assemblies Never place forklift fo
5. B8CGAOSZSZBZEZG Icons Battery status 2 Communication interface is activated RS232 IrDA M Bus g Meter is unlocked A Error message Q Empty pipe detection Battery Levels The battery icon indicates three levels of capacity Greater than 3 volts maximum 3 6V HN Greater than 2 volts less than 3 volts recommended battery replacement Less than 2 volts measuring has stopped Page 18 MAG UM 00219 EN 04 August 2014 M5000 MAIN MENU PROGRAMMING OPTIONS The following M5000 programming options are available from the Main Menu Meter Setup Measure In Out Communication Miscellaneous Information Pin Faults The applicable security level for each menu option is indicated as follows 5 v B August 2014 MAG UM 00219 EN 04 M5000 main menu programming options Administrative Service User Parameters indicated by the battery icon if changed will affect battery performance Page 19 Using the m5000 main menu programming options USING THE M5000 MAIN MENU PROGRAMMING OPTIONS Display Menu Screen Hierarchy Structure Main_Menu gt Page 20 Meter Setup Measure In Out Communication gt Miscellaneous gt Info gt PINs gt Faults Calibration Scale Factor Frequency Period Empty Pipe Flow Unit Totalizer Unit Full Scale Flow Low Flow Cutoff Flow Direction Totalizer1 Reset Median Filter Display Simulation Digital Input Outputs Interface R
6. ModMAG w series m5000 M Series B MAG Electromagnetic Flow Meters Electromagnetic Flow Meter Badger Meter User Manual M Series M5000 Electromagnetic Flow Meter Page ii MAG UM 00219 EN 04 August 2014 User Manual CONTENTS Safety Precautions and Instructions 2h hh hh hh 5 System Description ce RR SURE QR RE DR 5 Uripacking and Inspection 24 43 48 Ro reus Ro etd oe CR RC ROS Sada eta onda etd s 6 Rigging Lifting and Moving Large 5 2 22 2 6 Meter Location Orientation and 2 8 Remote Amplifier Outdoor Location 8 Pipelines and Fluid FloW zx achte aces Ae dw Re Ge e Ro a Ru 8 Meter OrientallOn RUE ake ha RUP EO OP ER EG OP URGE OP RUE UR 5 9 V rtical Placements socer a E ate owes c en S RU 9 Horizontal Placementer aks ca ao ee awd ak SUR AUS ACA ROS ULAHE GRON OR SRA dee PRS Raa NA X E prede 8 9 Straight ue sce Roe eee on b poe UR Ra eR EA E PR RW 9 Pipe Reducer
7. ft h Cubic Feet Hour bbl min Barrel Min Totalizer Unit This parameter establishes the units of measure for the totalizers U Display Totalizer Unit L Liters hL Hectoliter m Cubic Meters ft Cubic Feet gal U S Gallons MG Million Gallons IG Imperial Gallons bbl Barrel OZ Fluid Ounces ac ft Acre per foot Full Scale Flow This parameter sets the maximum flow that the system is expected to measure This parameter has influence on other system parameters which include Ss Low Flow Cutoff Changes to full scale flow affect the measuring cut off threshold of the meter Alarm Outputs Changes to full scale flow adjusts the thresholds for generating setpoint alarms Pulse Outputs Changes to full scale flow adjusts the pulse frequency and duty cycle Change the full scale flow based on the meter size and the application s requirements Verify that the full scale flow falls within the meter s suggested flow range limits Flow Range 0 1 32 8 ft s 0 03 10 m s The full scale flow is valid for both flow directions NOTE If the flow rate exceeds the full scale setting of more than 100 a FLOW OVERLOAD WARNING message indicates that the configured full scale range has been exceeded However the meter will continue to measure This will affect the latency of the pulse outputs and possibly cause overflow August 2014 MAG UM 00219 EN 04
8. BLUE WHITE ELECTRODE Et WHITE q Z Y PINK 0 _ M5000 JUNCTION BOX 44 SHIELD EMPTY PIPE 40 H 40 SHIELD 44 44 SHIELD ELECTRODE 46 46 ELECTRODE SHIELD 44 H 44 SHIELD 45 45 ELECTRODE O FROM DETECTOR TO AMPLIFIER 13 COIL 12 12 com Bue mitt con COIL RED BROWN NOTES 1 INDIVIDUAL CONDUCTOR SHIELDS DISCONNECTED ON AMPLIFIER SIDE 2 OUTER SHIELD CONNECTED ONLY BY 7 7 MEANS OF CABLE GLAND O Figure 20 Wiring for Remote Configuration August 2014 MAG UM 00219 EN 04 Page 15 Configuring input output i o CONFIGURING INPUT OUTPUT 1 0 This section describes wiring the following M5000 outputs Digital outputs Communication When the sensor and the amplifier have been wired wire any outputs to the M5000 amplifier Follow all of the safety precautions and local code to prevent electrical shock and damage to the electronic components Circuit Board Diagram Direction x oupu RED ADE_CLOCK G E SEP HS GREENADE DATA 2 BLACK ADE_GROUND 8 Coil G a Coil 2 4 68 eni SHE Figure 21 Configuring Input Output Input Output Descr
9. Battery Replacement ius c ERI eda UR GR UR Tb eh ee ee EORR Roe 14 Remote Mount Installation RUE UR ee abs ee ean 14 August 2014 MAG UM 00219 EN 04 Page iii M Series M5000 Electromagnetic Flow Meter Mount Bracket to Amplifier cR ee oe eae DAG ae be eg Rak hae RUNS 15 Wiring Configuration 2 ice cae eae ee ae RS CERES Roa Sheed RUE E ar RUN 15 Wiring for Remote Configuration s sares aa sase peda hh hh has 15 Configuring Input Output ss a SE RODA e Nu REN A ARE cakes Se 15 Circuit Board 3 usce eg sea oce aero ex em dor doe go or qv Qe e ee 16 Digital Output Wiring Diagrams cab aed ceed He ERAS ASUS GREG AS awa NOR x e dL S 17 DigitaliQutput Selectiolis uoce om ORO NUR ERIS a eae ONT deg 17 Programming the 5000 sisse ker m CEO PERE TEER OR KORR E 18 FUNCTION BUTIONS 35504 are a CR RR ale we aw la WW e a ee ha wee t 18 Display Peace EIUS lw EE DEO AY Be eae GE D mU al RODA A ae RUE 18 In I TTC 18 Battery levels s senum ar Ue aC NOR UR bah SR a ak aN RHET RG 18 M5000 Main Menu Programming Options
10. at ambient temperature Fluid Temperature With Remote Amplifier PTFE 302 F 150 Hard rubber 178 F 80 C With Meteis Mounted Amplifier PTFE 212 F 100 C Hard rubber 178 F 80 C Ambient Temperature 4 140 F 20 60 C Flow Direction Uni directional or bi directional Two separate programmable totalizers for uni directional measurement Outputs 4 digital Galvanically isolated open collector 30V DC maximum 20 mA each maximum output frequency at 100 Hz Outputs ADE High low flow alarm 0 100 of flow error alarm empty pipe alarm flow direction Communication RS232 Modbus RTU IrDA Empty Pipe Detection Field tunable for optimum performance based on specific application Min Max Flow Alarm Programmable outputs 0 100 of flow Low Flow Cut Off Programmable 0 10 of maximum flow Galvanic Separation Functional 50 volts Pulse Width Programmable 5 500 ms Coil Power Pulsed DC Repeatability 0 196 Sampling Rate Programmable from 1 to 63 seconds Standard sampling period is 15 seconds Display Two lines x 15 characters 7 on top 8 on bottom LCD display Programming Three external buttons Units of Measure Gallons ounces MGD liters cubic meters cubic feet imperial gallon barrel hectoliter and acre feet Amplifier Housing Battery Life 10 years Power Supply Internal lithium batteries 3 6 volt Processing L
11. messages Dial 4 9 Resolution 0 0001 10000 August 2014 MAG UM 00219 EN 04 Page 27 Using the m5000 main menu programming options Miscellaneous Menu Misc Battery Voltage Displays the current battery voltage This parameter is Read Only Battery Ah Displays the current battery capacity For example 0 38Ah to 38 38Ah This parameter is Read Only NOTE Anew battery should be at or near a 0 38 reading Language This parameter allows changing the current language English is the default setting a The following languages are supported German Deutsch Czech Cestina Spanish Espanol French Francais Russian Italian Italiano Day Month Year A real time calendar The day month and year must be reprogrammed after the battery is replaced A real time clock The hour minute and second must be reprogrammed after the battery is replaced gt Format the EEPROM to erase log files Totalizers and configuration remain unaffected during a format t et et fb lt Saves Totalizers to nonvolatile memory in preparation for battery replacement 22 start BD Provides the ability to reset the meter electronics I D Free hD Indicates the amount of free flash memory space Polarity Measured electrode polarizing voltage just for service purposes Datalogger The logging period can be adjusted to the following v
12. must be considered with the Pulse Width and Full Scale Flow parameters The maximum pulse frequency is 100 Hz The frequency is correlated with the flow rate Violation of output frequency limits will generate a PULSE_ OVERLOAD_WARNING Width 58 This parameter establishes the ON duration of the transmitted pulse The configurable range is 0 500 ms The factory default is 0 ms Non zero pulse width configuration the OFF duration of the transmitted pulse is dependent on flow rate The OFF duration is to be at least the configured ON duration At full scale flow the ON duration equals the Off duration The maximum configurable output frequency is limited to 100 Hz The duty cycle of the transmitted pulse is at 5096 of the output frequencies greater than 1 Hz This parameter must be considered with the Pulses Unit and Full Scale Flow parameters The maximum pulse frequency is 100 Hz The frequency is correlated with the flow rate Violation of output frequency limits will generate a PULSE_ OVERLOAD WARNING Power Line Frequency This parameter provides measuring immunity to industrial noise from power supply feed This parameter should be set to your nominal line frequency typically 50 Hz August 2014 MAG UM 00219 EN 04 Page 25 Using the m5000 main menu programming options Inputs Outputs Digital Outputs continued Set Min LS This parameter establishes as a percentage
13. options Meter Setup Menu Meter Setup Calibration Diameter This parameter is set at the factory In the event the amplifier is replaced verify that the pipe diameter matches the installed pipe size Detector Factor This parameter is set at the factory This factor compensates for accuracy a error as a result of the installed detector A In the event the amplifier is replaced this parameter must be reprogrammed with the original detector zero Detector Zero This parameter is set at the factory This parameter compensates for accuracy error as a result of the installed A detector In the event the amplifier is replaced this parameter must be reprogrammed with the original detector factor Amplifier Factor This parameter is set at the factory and is Read Only This factor compensates for accuracy error as a result of the installed amplifier Coil Current This parameter is set at the factory and is Read Only This factor compensates for accuracy error as a result of the installed amplifier Scale Factor LS Changing the scale factor lets you adjust the meter s accuracy without disturbing parameters set by the factory You can tune the meter to meet changing application requirements Power Line Frequency 5 This parameter is set at the factory This parameter provides measuring immunity to industrial noise from a power supply feed Period This parameter configures the frequ
14. with PVC fiberglass or concrete IMPORTANT It is essential that the mag meter amplifier s input ground zero voltage reference be electrically connected to the liquid media and to a good solid earth ground reference Conductive Pipe Grounding To achieve an adequate ground the meter body MUST be electrically connected to the liquid media The mag meter flanges are provided with grounding bolts for this purpose If the pipe material is electrically conductive simply install grounding straps between these grounding bolts and the mating flanges To ensure a good electrical connection at the mating flanges we recommend that you drill and tap the flanges and install a grounding screw not provided These grounding straps must be copper wire at least 12 AWG size They must be connected on both sides inlet and outlet of the detector and to a local earth ground Non Conductive Pipe Grounding IMPORTANT Ifthe process pipe is not electrically conductive PVC fiberglass cement lined pipes or any other non conductive material and the meter was not originally ordered with an optional grounding electrode you must install a pair of grounding rings between the mating flanges at both ends of the meter See the following illustration In this case the grounding straps should be connected to both of the ddr grounding rings and to a good solid earth ground Grounding rings are available in stainless steel If your fluid is too aggressive fo
15. 6P enclosures are constructed for indoor or outdoor use to provide protection against access to hazardous parts to provide a degree of protection against ingress of solid foreign objects and water hose directed water and the entry of water during prolonged submersion at a limited depth that provide an additional level of protection against corrosion and that will be undamaged by the external formation of ice on the enclosure WIRING Wiring Safety AT INSTALLATION BE SURE TO COMPLY WITH THE FOLLOWING REQUIREMENTS Disconnect power to the unit before attempting any connection or service to the unit Do not bundle or route signal lines with power lines Keep all lines as short as possible Use twisted pair shielded wire for all output wiring e Observe all applicable local electrical codes Opening the M5000 Cover The M5000 amplifier s design lets you open the cover without completely removing it Follow these steps 1 Completely remove the top two screws from the amplifier using a blade slotted screwdriver 2 Loosen both of the bottom screws so that the round head of each screw clears the top face of the cover 3 Pull the cover down to the open position Figure 17 Remove Two Screws Figure 18 Open the Cover August 2014 MAG UM 00219 EN 04 Page 13 Battery BATTERY Use a two D cell battery pack 1 2 to 6 or a double two D cell battery pack 8 to 24 Battery Life Standard Pack Sampl
16. OPEN MINIMUM STRAIGHT PIPE MINIMUM STRAIGHT PIPE GLOBE VALVE BUTTERFLY VALVE 7 0 STANDARD CONCENTRIC P MINIMUM STRAIGHT PIPE REDUCERS NO DISTANCE REQUIRED CHECK VALVE MINIMUM PIPING REQUIREMENT Figure 8 Straight Pipe Requirements August 2014 MAG UM 00219 EN 04 Page 9 Meter location orientation and applications Pipe Reducer Requirements With pipe reducers a smaller 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 required amount of straight pipe Flow Meter D Pipe Size D Pipe Size Forward Flow Custom Fabricated Reducers 15 Degree Slope Angle NE Standard Concentric Reducers No Distance Required Figure 9 Pipe Reducer Requirements Chemical Injection Applications For water line applications with a chemical injection point install the meter upstream of the injection point This eliminates any meter performance issues CHEMICAL Flow Meter INJECTION FORWARD FLOW UPSTREAM DOWNSTREAM Figure 10 Chemical Injection Point Upstream of Meter If a meter must be installed downstream of a chemical injection co
17. Page 23 Using the m5000 main menu programming options Measure Low Flow Cutoff Low flow cutoff defines the threshold at which flow measurement will be forced to zero The cutoff value can be set from 096 to 1096 of the full scale flow Increasing this threshold will help prevent false U readings during no flow conditions possibly caused by pipe vibration or inherent system noise Flow Direction This parameter allows setting the meter to measure forward flow only unidirectional or both forward a and reverse flow bidirectional LS Unidirectional Flow is totalized in only one direction The flow direction is indicated by the arrow printed on the detector label Unidirectional measurements on the main display screen include T1 Registers forward flow resettable by menu or Modbus RTU T2 Registers forward flow non resettable Bidirectional Flow is totalized in both directions Bidirectional measurements on the main display screen include T1 Registers forward flow resettable by menu or Modbus RTU T1 Registers reverse flow resettable by menu or Modbus RTU T1N Registers total flow T T resettable by menu or Modbus RTU T2 Registers forward flow non resettable T2 Registers reverse flow non resettable T2N Registers total flow T T non resettable T1 Reset This parameter allows the reset of totalizer T1 Median This parameter can be set to ON or OFF When set to ON the median display fil
18. S 232 MODBUS M Bus ADE Battery Voltage Battery Capacity Language Date DMY Time EEPROM Battery Restart HDD Free Polar V Datalogger Serial Number Version Compilation Date OtpCrc AppCrc Control User Service Admin Random Emergency Preamp Coil Empty Pipe Measure Time Voltage Overflow MAG UM 00219 EN 04 August 2014 Security SECURITY The M5000 security feature allows the option to restrict access to the meter by way of a 6 digit Personal Identification Number PIN The system administrator can set up a single PIN for each of the three different levels of access Administration allows access to all M5000 menu configuration screens Service allows access to service level and user level menu configuration screens User allows access only to user level menu configuration screens NOTE Foralost PIN Contact Badger Meter Technical Support at 800 456 5023 for a replacement PIN Not all levels of access need to be set If no PINs are set up any M5000 user will have access to all functions NOTE The security settings will also apply to remote access All remote writes via Modbus to the meter will be blocked unless the user is remotely logged in Setting a PIN From the Main Menu press the right arrow button From the Meter Setup menu press the up arrow button until the Pin menu is displayed Press the right arrow button to display the PINS Control menu Press the right arrow button to f
19. ach hour For an Coil explanation of the error that has occurred or how to fix it see Errors amp Warnings on page 32 Empty Pipe Measure Time Volume Overflow August 2014 MAG UM 00219 EN 04 Page 29 Maintenance MAINTENANCE Mandatory routine or scheduled maintenance should not be required for the M5000 Mag Meter electronics or flow tube after proper installation However some occurrences may require personnel to perform the following Flow tube and electrode cleaning Circuit board replacement DO NOT CLEAN COMPONENTS INSIDE THE AMPLIFIER OR JUNCTION BOX Cleaning the Flow Tube and Electrode 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 Material Safety Data Sheet MSDS guidelines for the products s that were in contact with the flow tube and electrodes Should flow tube and or electrode cleaning become necessary 1 Disconnect detector from pipeline 2 Clean electrodes according to MSDS guidelines 3 Reconnect detector to pipeline Page 30 MAG UM 00219 EN 04 August 2014 Troubleshooting TROUBLESHOOTING The M5000 mag meter is designed for many years of optimal performance However should it malfunction there are certain things that we recommend you
20. alues 1min 15min 1h 6h 12h 24h See the Datalogging User Manual for more information Information Menu Info Serial Number Serial number of the electronic board Version Software version of the device Compilation Date Date of the software version OPT CRC Checksum of the software update APP CRC Checksum of the application Page 28 MAG UM 00219 EN 04 August 2014 Using the m5000 main menu programming options PIN Menu PIN Control Two options are available ON requires PIN configuration A OFF User Users logged in with this PIN have access to all user levels Users at this level do not have access to Service or Admin functions Service Users logged in with this PIN have access to both service and user level procedures Users at this level do not have access to Admin functions Admin Users logged in with this PIN have access to all procedures Users at this level have full access to the meter A Random This function generates a random number which is used when a PIN is lost This number will be needed for Badger Meter Tech Support to provide a Master PIN Emergency Enter the Master PIN received from Badger Meter Technical Support to unlock the meter in case the Admin PIN has been lost Faults Menu Faults Preamp The Faults menu displays the errors and the number of time they have occurred e
21. are settable from 0 100 in 196 increments August 2014 MAG UM 00219 EN 04 Outputs are configurable for Pulses Unit PPU and Pulse Width PW The PW is configurable from 5 500 milliseconds with a Page 17 Programming the m5000 PROGRAMMING THE M5000 The M5000 amplifier is pre programmed from the factory No additional programming is necessary however for special features the meter can be programmed for specific requirements Function Buttons All M5000 programming is accomplished using the three function buttons located on the front of the amplifier Screen navigation and digit and parameter selection is performed by a gt yis combination of these three buttons The up arrow button allows scrolling through seven menu screens This button is also used to advance numerical digits to change values such as frequency period and EP level as well as toggle on off conditions and flow directions The right arrow button allows digit selection from left to right and allows selecting either the top row of the display or the bottom row the bottom row is active when flashing The EXIT SAVE button allows the saving of changed values and conditions toggling between the upper and lower display lines and returning to a previous menu Display The top row displays seven digits for specific values on each screen and the bottom row ea displays meter and register condition icons and current screen descriptions
22. check before contacting our Technical Support department or your local Badger Meter Representative NOTE Ifthe fluid measured has a high concentration of conductive solids deposits may accumulate on the internal liner walls and electrodes These deposits will cause a reduction of the measuring output Thus Badger Meter recommends that you remove the meter and inspect the liner and electrodes after six months If deposits are found remove them with a soft brush Repeat inspection process every six months or until an appropriate inspection cycle can be established for the specific application Other general conditions include Description Possible Cause Recommended Action Flow is present but Disconnected signal cable Check signal cable display is 0 Detector mounted opposite of the main Flow Turn detector 180 or switch terminal E1 and E2 direction see arrow on the nameplate or reprogram to bidirectional mode Coil or electrode cables exchanged Check cable connections for cross wiring Improper low flow cutoff or full scale flow Replace configuration defaults Inaccurate Improper calibration measuring Check the parameters detector factor and size according to supplied data sheet Wrong calibration parameter Pipe not fully filled or air in pipe Check if meter is completely filled with fluid Invalid fluid conductivity Purge line to eliminate air bubbles Invalid fluid mixture 9
23. ctor The construction materials of the wetted parts liner and electrodes should be appropriate for the specifications on the intended type of service We recommend that you review all of the compatibilities consistent with the specifications Each meter is factory tested and calibrated A calibration certificate is included with each meter August 2014 MAG UM 00219 EN 04 Page 5 Unpacking and inspection UNPACKING AND INSPECTION Follow these guidelines when unpacking the M Series equipment NOTE NOTE If a shipping container shows any sign of damage have the shipper present when you unpack the meter Follow all unpacking lifting and moving instructions associated with the shipping container Open the container and remove all packing materials Store the shipping container and packing materials in the event the unit needs to be shipped for service Verify that the shipment matches the packing list and your order form Inspect the meter for any signs of shipping damage scratches or loose or broken parts If the unit was damaged in transit it is your responsibility to request an inspection report from the carrier within 48 hours You must then file a claim with the carrier and contact Badger Meter for appropriate repairs or replacement All detectors with polytetrafluoroethylene PTFE liners are shipped with a liner protector on each end to maintain proper form of the PTFE material during shipping and storage
24. ency 1 4 1 99 seconds of sampled measurements In other 2 a words if set to 15 then every 15 seconds it will sample for 208 micro seconds A NOTE Parameters indicated by the battery icon if changed will affect battery performance Standard sampling period is 15 seconds Empty Pipe Detection Empty Pipe ON OFF When set to ON an Empty Pipe condition indicates to the outputs a that the meter is not completely filled When set to OFF empty pipe 5 conditions are not detected Threshold This parameter is set at the factory and adjusted to the conductivity of a normal water Measure Measures the real empty pipe value This parameter is Read Only Page 22 MAG UM 00219 EN 04 August 2014 Using the m5000 main menu programming options Measure Menu Measure This parameter establishes the unit of measure for the flow rate and full scale flow Changing this Flow Unit a parameter readjusts the full scale flow parameter For example changing from GPM to GPS would change the full scale flow from 60 gal min to 1 gal s Display Flow Unit Display Flow Unit L s Liters Second gal s Gallons Sec L min Liters Minute gal min Gallons Min L h Liters Hour gal h Gallons Hour m s Cubic Meters Sec MG d MillionGallons Day m min Cubic Meters Min IG s ImperialGallons Sec m h Cubic Meters Hour IG min ImperialGallons Min ft3 s Cubic Feet Sec IG h ImperialGallons Hour ft m Cubic Feet Min oz min Ounce Min
25. er the pulse number FLOW OVERLOAD WARNING Flow exceeded the Full Scale of more than 100 Set the flow range properly LOW POWER WARNING Battery voltage is smaller than 3 0V Consider replacing the battery EEPROM ERROR Configuration file is missing Replace the board CONFIG ERROR Configuration file is corrupted Replace the board PREAMPLIFIER OVERLOAD Input voltage exceeded the limits Maximum polarization is 227 mV maximum power line noise is 10 6 mV maximum useful signal is 10 7 mV Empty detector Switch Empty Pipe detection ON Dirty electrodes Clean the electrodes COIL ERROR Coil sensor is not connected Make sure wiring is properly connected to the Coil shorted amplifier Issue with coil current If that does not clear the alarm contact Badger Meter Technical Support Page 32 MAG UM 00219 EN 04 August 2014 SPECIFICATIONS Flow Range Specifications 0 1 32 8 ft s 0 03 10 m s Accuracy 0 50 rate for velocities greater than 1 64 ft s 0 50 m s 0 008 ft s 0 0025 m s for velocities less than 1 64 ft s 0 50 m s Minimum Fluid Conductivity Pressure Limits gt 20 micro siemens cm Maximum allowable non shock pressure and demn peranre ratings for steel pipe flanges according to American National Standard ANSI Examples 150 Ib flange rated 285 psi at ABER 300 Ib flange rated 740 psi
26. essure applications and it prevents solids build up sediment deposit and accumulation on the liner and electrodes NOTE Carefully observe the Forward Flow label on the meter body and install the meter accordingly When installed vertically rotate amplifier so that cable glands are facing down Horizontal Placement M5000 meters are equipped with an Empty Pipe Electrode Detection feature If an electrode mounted in the pipe is not covered by fluid for five seconds the meter will Be oe display an Empty Pipe Detection condition The meter will send out an error message and stop measuring RIGHT WRONG flow When the electrode is again covered with fluid Figure 7 Horizontal Placement the error message disappears and the meter will begin measuring When installing the meter on a horizontal pipe mount the detector to the pipe with the flow measuring electrode axis in a horizontal plane three and nine o clock This placement helps prevent solids build up sediment deposit and accumulation on the electrodes Straight Pipe Requirements FLOWMETER Sufficient straight pipe runs are required at the detector inlet and outlet for optimum meter accuracy and performance An equivalent of three diameters of straight pipe is required on the inlet upstream side Two diameters are required on the outlet downstream side D Pipe Size D Pipe Size FORWARD FLOW ELBOW TEE GATE VALVE 3xD FULLY
27. eter If vibrations cannot be restrained mount the amplifier in a remote location Do install the detector close to pipeline valves fittings or impediments that can cause flow disturbances e For detectors with PTFE liners do not install the detector on suction sides of pumps Do install the detector on outlet sides of piston or diaphragm pumps Pulsating flow can affect meter performance e Avoidinstalling the detector near equipment that produces electrical interference such as electric motors transformers variable frequency and power cables e Verify that both ends of the signal cables are securely fastened e Place power cables and signal cables in separate conduits Place the meter where there is enough access for installation and maintenance tasks 8 MAG UM 00219 EN 04 August 2014 Meter location orientation and applications 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 perform best when placed vertically with liquid flowing upward and meter electrodes in a closed full pipe Figure 6 Vertical Placement Vertical placement allows the pipe to remain completely full even in low flow low pr
28. 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 2014 Badger Meter Inc All rights reserved www badgermeter com The Americas Badger Meter 4545 West Brown Deer Rd PO Box 245036 Milwaukee WI 53224 9536 800 876 3837 414 355 0400 M xico Badger Meter de las Americas S A de C V Pedro Luis Ogaz n N 32 Esq Angelina N 24 Colonia Guadalupe Inn CP 01050 M xico DF M xico 52 55 5662 0882 Europe Middle East and Africa Badger Meter Europa GmbH Nurtinger Str 76 72639 Neuffen Germany 49 7025 9208 0 Europe Middle East Branch Office Badger Meter Europe PO Box 341442 Dubai Silicon Oasis Head Quarter Building Wing C Office 209 Dubai UAE 971 4 371 2503 Czech Republic Badger Meter Czech Republic s r o Ma kova 2082 26 621 00 Brno Czech Republic 420 5 41420411 Slovakia Badger Meter Slovakia s r o Racianska 109 B 831 02 Bratislava Slovakia 421 2 44 63 83 01 Asia Pacific Badger Meter 80 Marine Parade Rd 21 06 Parkway Parade Singapore 449269 65 63464836 China Badger Meter 7 1202 99 Hangzhong Road Minhang District Shanghai China 201101 86 21 5763 5412 832
29. ing uoto ack aoe ha he NEN NE NEN EN a CENE CX CEN EN Wa CAEN NE 31 Errors amp Wathiligs i s esser one ER AK Ow ok dra ege ow POR a e i Rum bod 32 SpecifiCatiOns s susce teak SERE SUR GER UR SERA E Du E LRL AER C B aud GU d S SECUS TS RERO 33 Page iv MAG UM 00219 EN 04 August 2014 Safety precautions and instructions SAFETY PRECAUTIONS AND INSTRUCTIONS Some procedures in this manual require special safety considerations In such cases the text is emphasized with the following symbols Symbol Explanation Warning indicates the potential for severe personal injury death or substantial property damage Comply with the instructions and proceed with care Caution indicates the potential for minor personal injury or property damage Comply with the instructions and proceed with care SYSTEM DESCRIPTION The Badger Meter M Series model M5000 electromagnetic flow meter is intended for fluid metering in most industries including water wastewater food and beverage pharmaceutical and chemical The basic components of an electromagnetic flow meter are The detector which includes the flow tube isolating liner and measuring electrodes The amplifier which is the electronic device responsible for the signal processing flow calculation display and output signals Nm z3 lt Detector Figure 1 Amplifier and Dete
30. ing Expected Life 0 25 3 months 4 4 years 8 8 years 15 10 years These calculations are for a standard battery pack with two D size batteries with communication and outputs OFF at a temperature of 77 F 259 C Battery Replacement 1 Goto Main Menu Misc Battery Change and select the capacity of the battery pack which should be installed see label on the battery pack 19 Ah 38 Ah or 70 Ah Press E to quit The display freezes no reaction by pressing any button 2 Open the cover 3 Remove all connectors detector and outputs 4 Remove all 4 screws of the main board remove the circuit board and disconnect the old battery 5 Remove the old battery and wait about 2 minutes before replacing it with a new one LCD display should be off 6 Plug the battery connector into the back of the main board and reinstall the circuit board 7 Replace all the plugs 8 Close the cover tight 9 Checktime and date Main Menu Misc Time and Main Menu Misc Date DMY 10 Check capacity of battery Main Menu Misc Battery AH The first value is the used capacity which should be 0 0 The second value is the capacity of the battery pack Battery AH is a read only parameter NOTE Totalizers and configuration remain unaffected during battery replacement Figure 19 Amplifier Housing Components Exploded View Remote Mount Installation If you are installing the M5000 amplifier in a
31. iption Terminal Output 1 Passive max 30V DC 20 mA OUT1 Max Frequency 100 Hz Output 2 Passive max 30V DC 20 mA OUT2 and Max Frequency 100 Hz Output 3 Passive Max 30V DC 20 mA OUT3 Output 4 Passive Max 30V DC 20 mA OUT4 and Can be used with digital input as an ADE interface RS232 Modbus RTU RxD TxD GND IN Digital input 3 35V DC IN and M BUS M Bus interface No polarity Page 16 MAG UM 00219 EN 04 August 2014 Digital Output Wiring Diagrams Configuring input output i o Positive Pulse Logic Negative Pulse Logic NEC V wO U 22 20mA Vs30V Vis 30 gt 25 Signal Signal R Figure 22 Digital Output Wiring Diagram Digital Output Selections Output 2 Output 3 Output 4 Output 1 Forward Pulse Output Reverse Pulse Output Flow direction Forward vs Reverse Flow Setpoint 0 100 of full scale resolution 1 Flow Setpoint 0 100 of full scale resolution 1 Empty pipe alarm Empty pipe alarm ADE Error alarm Error alarm Off Test Can be used with AMR when the pulse width is set to 50 milliseconds frequency limit is 100 Hz The PPU is displayed using an automatically selected resolution The high low flow alarm functionality is configurable for maximum and minimum setpoints as a percentage of full scale flow Configurable values
32. lash ON or OFF With either ON or OFF flashing press the up arrow button to display ON Press the EXIT SAVE button to save the ON setting With the Control menu flashing press the up arrow button to display the desired security level user service or admin With the desired security level flashing press the right arrow button to display the upper row of six zeros digits 9 Pressthe up arrow button to change the first digit followed by pressing the right arrow button to select the next digit 10 Press the EXIT SAVE button to save the PIN number for that security level The saved PIN number will be the same PIN number used to log in to the amplifier ON Ov wr d ow No NOTE Be sure to log off when you have completed work with the M5000 Otherwise a five minute time delay occurs between the most recent activity and the time when the M5000 automatically logs off Logging In To change any parameter in the mag meter the PIN entered must provide the proper security privilege required by the parameter To enter a PIN go to the Login menu and enter the PIN for the required security level Once you are properly logged in the unlocked icon appears on the meter display NOTE APIN Error message displays if the incorrect PIN is entered Logging Out To log out follow steps 1 through 8 under Setting a PIN At step 9 enter an unknown PIN then press EXIT SAVE August 2014 MAG UM 00219 EN 04 Page 21 Using the m5000 main menu programming
33. m side Figure 12 Incorrect Meter Placement Figure 13 Position Valves on Downstream Side To minimize the possibility of partially full pipe flows in horizontal gravity or low pressure applications create a pipe arrangement that ensures the detector remains full of liquid at all times ji P Figure 14 Pipe Positioned to Keep Water in Detector August 2014 MAG UM 00219 EN 04 11 Meter gaskets and grounding METER GASKETS AND GROUNDING Gasket and grounding requirements must be considered when determining the meter location orientation and application Meter Pipeline Connection Gaskets You must install gaskets not provided between the detector s isolating liner and the pipeline flange to ensure a proper and secure hydraulic seal Use gaskets that are compatible with the fluid Center each gasket on the flange to avoid flow restrictions or turbulence in the line During installation do not use graphite or any electrically conductive sealing compound to hold the gaskets This could compromise the accuracy of the measuring signal GASKETS RECOMMENDED t Figure 15 Meter Pipeline Connection Gaskets If you are using a grounding ring in the detector pipeline connection place the ring between two gaskets See Non Conductive Pipe Grounding on page 12 Meter Grounding Process pipeline material can be either electrically conductive metal or not electrically conductive made of or lined
34. nnection the distance between the meter and the injection point should be between 50 and 100 feet 15 and 30 meters The distance must be long enough to allow the water or chemical solution to reach the meter in a complete homogeneous mixture CHEMICAL Flow Meter INJECTION FORWARD FLOW UPSTREAM i DOWNSTREAM Figure 11 Chemical Injection Point Upstream of Meter If the injection point is too close the meter senses the two different conductivities for each liquid This will likely result in inaccurate measurements The injection method spaced bursts continuous stream of drips or liquid or gas can also affect downstream readings by the meter Page 10 MAG UM 00219 EN 04 August 2014 Meter location orientation and applications Partially Filled Pipe Situations In some locations the process pipe may be momentarily only partially filled Examples include lack of back pressure insufficient line pressure and gravity flow applications To eliminate these situations Donot install the meter at the highest point of the pipeline not install the meter in a vertical downward flow section of pipe Always position the ON OFF valves on the downstream side of the meter WRONG RIGHT WRONG RIGHT 1 is it is B d L 5 Do not install in vertical downward position Position On Off valves on downstrea
35. of full scale flow the threshold at which the output alarm will be activated Flow rates below the threshold will activate the output alarm Set Max Ls This parameter establishes as a percentage of full scale flow the threshold at which the output alarm will be activated Flow rates above the threshold will activate the output alarm Out 1 Func Out 2 Func Out 3 Func Out 4 Func sf This parameter provides configuration of the functional operation of the associated output The following operations are supported Function Dig1 Dig2 Dig3 Dig4 Off Test MinMax Empty xxx xxi ErAlarm Forward gt lt gt lt gt lt gt lt lt lt gt lt gt lt Reverse Direct X ADE X Inactive Off means digital output is switched off It is recommended to switch off the outputs in the menu Output function if not used This increase the battery life time Test Test triggers the output Flow setpoint MinMax provides indication when flow rate exceeds thresholds defined by flow setpoints set min set max Empty pipe alarm Empty provides indication when pipe is empty Error alarm ErAlarm provides indication when meter has error condition Forward pulse Forward generates pulses during forward flow conditions Reverse pulse Reverse generates pulses during reverse flow conditions Flow direction Direct provide
36. ow power microcontroller 16 bit NEMA 4X IP66 cast aluminum powder coated paint Meter Housing Material Standard Carbon steel welded Pipe Spool Material 316 stainless steel Flanges Standard ANSI B16 5 Class 150 RF Cast steel Optional 316 stainless steel amp 300 cast steel Liner Material PTFE 0 5 24 Hard rubber 1 24 Electrode Materials Standard Alloy C Optional 316 stainless steel Mounting Detector mount or remote wall mount bracket supplied Meter Enclosure NEMA 4X IP66 Optional Submersible NEMA 6P IP67 remote amplifier required Classification Junction Box Enclosure Protection For remote amplifier option Powder coated die cast aluminum NEMA 4 IP66 NSF Listed Models with hard rubber liner 4 size and up PTFE liner all sizes Cable Entries 1 2 NPT Cord Grip Optional Stainless Steel Grounding Rings Meter Size Thickness of 1 ring Upthrough 1 0 135 12 24 0 187 August 2014 MAG UM 00219 EN 04 Page 33 M Series M5000 Electromagnetic Flow Meter INTENTIONAL BLANK PAGE Page 34 MAG UM 00219 EN 04 August 2014 User Manual INTENTIONAL BLANK PAGE August 2014 MAG UM 00219 EN 04 Page 35 Control Manage Optimize M SERIES and ORION are registered trademarks of Badger Meter Inc Other trademarks appearing in this document are the property of their respective entities Due to continuous research product
37. r stainless 4 Anal l steel order a meter with the optional grounding electrode in a material 0000 jg um 1 ff D 0 E a GROUNDING RING compatible with the fluid ey GASKETS RECOMMENDED Figure 16 Non Conductive Pipe Grounding Page 12 MAG UM 00219 EN 04 August 2014 Amplifier mounting configuration options AMPLIFIER MOUNTING CONFIGURATION OPTIONS Meter Mount Configuration The meter mount configuration has the amplifier mounted directly on the detector This compact self contained configuration minimizes installation wiring Remote Mount Configuration The remote mount configuration places the amplifier at a location away from the fluid flow and detector This is necessary in situations where process fluid temperature or the environment exceeds amplifier ratings The detector and amplifier are connected by wires run through conduit between junction boxes on the detector and the amplifier The distance between the detector junction box and amplifier junction box can be up to 100 feet 30 meters A remote mounting bracket is supplied Submersible Option If you are installing the meter in a vault you should order the remote amplifier option You must not install the amplifier inside a vault We also recommend ordering the remote meter package with the submersible option NEMA This will eliminate any potential problems resulting from humidity or temporary flooding in the vault NOTE NEMA
38. remote location review the procedures in this section Page 14 MAG UM 00219 EN 04 August 2014 Battery Mount Bracket to Amplifier 1 Align bracket mounting holes with amplifier mounting holes 2 Attach bracket to amplifier with supplied screws Torque the screws to 80 inch pounds Wiring Configuration Wiring between the detector and the M5000 amplifier comes complete from the factory If your installation requires the use of conduit we recommend that you follow these steps when wiring the detector to the amplifier 1 Carefully remove the wires connected to the terminal blocks that run to the M5000 amplifier or to the junction box See the chart below for a reference of wire color to terminal connection 2 Run cable through the conduit while retaining the wiring of the cable to the amplifier or the junction box as supplied 3 Complete conduit assembly on both ends and rewire the cable as it was previously wired Wiring for Remote Configuration Remote style M5000 amplifier models can be ordered with standard cables measuring 15 30 50 and 100 feet Junction Box bus ddl Description Wire Color 11 Coil Red Brown 12 Coil Blue White 13 Main Shield Not Used 40 Empty Pipe Pink 44 Shield Green 44 Empty Pipe Shield Shield Wire 45 Electrode White 46 Electrode Black Connections with the No 44 are lying on the same potential M5000 AMPLIFIER COIL d CT RED 8RONN 2
39. rks rigging chains straps slings hooks or other lifting devices inside or through the detector s flow tube to hoist the unit This could damage the isolating liner Do not lift detector with forklift Do not lift or rig lifting devices through detector Figure 4 Lifting and Rigging Cautions August 2014 MAG UM 00219 EN 04 Page7 Meter location orientation and applications METER LOCATION ORIENTATION AND APPLICATIONS The M5000 provides two amplifier mounting options an integral or meter mount option and a junction box remote option 0000 Meter mount amplifier Junction box with remote amplifier Figure 5 Amplifier Mounting Options Remote Amplifier Outdoor Location The amplifier can be installed and operated outdoors However it must be protected from the elements as follows The ambient environment temperature rating for the unit is 4 140 F 20 60 C If an indoor location is within 100 feet 30 meters of the detector consider increasing the cable length up to 100 ft and mounting the amplifier indoors e At minimum fabricate a roof or shield over and or around the amplifier to protect the LCD display screen from direct sunlight Pipelines and Fluid Flow Take the following precautions during installation Do not install the meter on pipes with extreme pipe vibrations If pipes are vibrating secure the piping with appropriate pipe supports in front of and behind the m
40. s indication on current flow direction ADE ADE Absolute Digital Encoder for remote meter reading using ASCII communication protocol Out 1 Type Out 2 Type Out 3 Type Out 4 Type LS This parameter lets you set the output switch to normally open or normally closed If normally open is selected the output switch is open no current when the output is inactive and closed current flows when the output is active If normally closed is selected the output switch is closed current flows when the output is inactive and open no current when the output is active Page 26 MAG UM 00219 EN 04 August 2014 Using the m5000 main menu programming options Communication Menu Communication Port Settings Interface This parameter provides communication port configuration IrDA Modbus RTU LS cu Serial Modbus RTU M Bus OFF turns off the serial interfaces Serial Baud Rate This parameter sets the baud rate ES The following baud rates are supported sm 9600 1200 2400 Parity This parameter sets the parity es The following parities are supported LS Even Odd Mark Modbus Address This parameter configures the Modbus address in the range from 1 247 LS M Bus Address MeterBus protocol mainly used in the European market Please direct R questions to Badger Meter Technical Support ADE Control ON OFF Protocol V1 standard messages V2 extended
41. ters out the flow rate fluctuations displayed on the LCD Filter Display This parameter can be set from 0 99 seconds The display will update less frequently depending on how high the filter display is set Page 24 MAG UM 00219 EN 04 August 2014 Inputs Outputs Menu Using the m5000 main menu programming options Inputs Outputs Flow Simulation LS Flow Simulation provides output simulation based on a percentage of the full scale flow Simulation will not accumulate the totalizers The range of simulation includes 100 100 of the full scale flow The Flow Simulation Parameter lets you set the range of simulation in increments of 50 OFF 0 50 100 50 100 The factory default is OFF Digital Input LS Digital input lets you reset totalizers or interrupt flow measurement Input switching is provided by applying an external voltage of 3 35V DC Use a normally open contact for operating Digital Outputs continued on next page Pulse Unit This parameter lets you set how many pulses per unit of measure will be transmitted to remote applications For example assuming the unit of measure is gallons Setting the Pulses Unit to 1 standard setting will transmit 1 pulse every gallon Setting the Pulses Unit to 0 01 will transmit 1 pulse every 100 gallons You must configure pulses unit if the function of the selected output is to be forward or reverse This parameter
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