Badger Meter M5000 Electromagnetic Flow Meter

M-Series® Mag Meter
Model M-5000
IMPORTANT:
This manual contains important information.
READ AND KEEP FOR REFERENCE.
IOM-832-01 (12-10)
PN: 53400-832 Rev. 1
Installation &
Operation Manual
Model M-5000 Mag Meter
Page ii
(12-10)
Installation & Operation
Table of Contents
Safety Precautions and Instructions................................................................................................5
System Description...........................................................................................................................5
Unpacking and Inspection................................................................................................................5
Meter Location, Orientation and Applications...............................................................................8
Pipelines and Fluid Flow.................................................................................................................................................8
Meter Orientation............................................................................................................................................................8
Pipe Reducer Requirements...........................................................................................................................................10
Meter/Pipeline Connection Gaskets.............................................................................................................................................................................................................................. 13
Meter Grounding.................................................................................................................................................................................................................................................................. 14
Conductive Pipe Grounding............................................................................................................................................................................................................................................. 14
Non-Conductive Pipe Grounding................................................................................................................................................................................................................................... 14
Amplifier Mounting Configuration Options..................................................................................................................14
Meter Mount Configuration............................................................................................................................................................................................................................................. 14
Remote Mount Configuration......................................................................................................................................................................................................................................... 15
Submersible Option........................................................................................................................................................15
Wiring...............................................................................................................................................................................15
Wiring Safety.......................................................................................................................................................................................................................................................................... 15
Opening the M-5000 Cover.............................................................................................................................................16
Power................................................................................................................................................17
Battery..............................................................................................................................................................................17
Battery Life.............................................................................................................................................................................................................................................................................. 17
Battery Replacement.......................................................................................................................................................17
Remote Mount Installation.............................................................................................................................................19
Mount Bracket to Amplifier.............................................................................................................................................................................................................................................. 19
Wiring Configuration.......................................................................................................................................................................................................................................................... 19
Wiring for Remote Configuration................................................................................................................................................................................................................................... 19
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Page iii
Model M-5000 Mag Meter
Configuring Output............................................................................................................................................................................................................................................................. 21
Circuit Board Diagram........................................................................................................................................................................................................................................................ 21
Digital Output Wiring Diagrams..................................................................................................................................................................................................................................... 22
Programming the M-5000..............................................................................................................23
Function Buttons.............................................................................................................................................................23
Display..............................................................................................................................................................................23
Battery Levels......................................................................................................................................................................................................................................................................... 23
Display Menu Screen Hierarchy Structure.....................................................................................................................24
Security............................................................................................................................................25
Setting a PIN....................................................................................................................................................................25
M-5000 Main Menu Programming Options...................................................................................27
Maintenance....................................................................................................................................38
Cleaning the Flow Tube and Electrode..........................................................................................................................38
Troubleshooting..............................................................................................................................39
Errors & Warnings............................................................................................................................................................40
Detector Specifications...................................................................................................................41
Amplifier Specifications..................................................................................................................42
Page iv
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Installation & Operation
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
When attached to the product, this symbol indicates a potential hazard. Review
the documentation to determine the nature of the potential hazard and any
required actions or precautions.
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 M-5000 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.
Amplifier
®
Detector
The construction materials of the wetted parts (liner and electrodes) should be appropriate for the specifications
on the intended type of service. Make sure to review all of the compatibilities consistent with the specifications.
Each meter is factory tested and calibrated. A calibration certificate is included with each meter.
Unpacking and Inspection
Follow these guidelines when unpacking the M-Series equipment.
• If a shipping container shows any sign of damage, have the shipper present when unpacking 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 order form.
• Inspect the meter for any signs of shipping damage, scratches, or loose or broken parts.
Note: If the unit was damaged in transit, request an inspection report from the carrier within 48 hours. A
claim must be filed 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.
Note: Do not remove the liner protectors until installation.
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Page 5
Model M-5000 Mag Meter
• Storage: If the meter is to be stored, place it in its original container in a dry, sheltered location. Storage temperature ranges are: -40°F to 160°F (-40°C to 70°C).
Rigging, Lifting and Moving Large Units
When rigging, lifting or moving large units, follow these guidelines.
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.
Use the sling-rigged method to lift large detectors into a vertical position while they are still crated. Use this
method to position large detectors vertically into pipelines.
Page 6
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Installation & Operation
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 forks, 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.
(12-10)
Do not lift or rig lifting devices through detector.
Page 7
Model M-5000 Mag Meter
Meter Location, Orientation and Applications
The M-5000 provides two amplifier mounting options: an integral or meter mount option and a junction box/
remote option.
Meter mount amplifier Junction box with remote amplifier
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° F to 140° F (-20° C to 60° C).
• If an indoor location is within 100 feet (30 meters) of the detector, consider increasing the cable length
and mounting the amplifier indoors.
• 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 meter. If vibrations can’t be restrained, mount
the amplifier in a remote location.
• Do not install the detector close to pipeline valves, fittings or impediments that can cause flow disturbances.
• For detectors with PTFE liners, do not install the detector on suction sides of pumps.
• Do not install the detector on outlet sides of piston or diaphragm pumps. Pulsating flow can affect meter
performance.
• Avoid installing the detector near equipment that produces electrical interference such as electric motors,
transformers, variable frequency, power cables, etc.
• Verify that both ends of the signal cables are securely fastened.
• Place power cables and signal cables in separate conduits.
• Place the meter where there is enough access for installation and maintenance tasks.
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.
Page 8
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Installation & Operation
Vertical Placement
Mag meters perform best 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 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.
Horizontal Placement
M-5000 meters are equipped with an "Empty Pipe Detection" feature. If an electrode mounted in the pipe is not
covered by fluid, the meter will display an "Empty Pipe Detection" condition. The meter will send out an error
message and stop measuring flow. When the electrode is again covered with fluid, 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.
Electrode
Plane
Electrode
Plane
RIGHT
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WRONG
Page 9
Model M-5000 Mag Meter
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 diameters of straight pipe is required on the inlet (upstream) side. Two diameters are
required on the outlet (downstream) side.
FLOWMETER
D (Pipe Size)
D (Pipe Size)
FORWARD FLOW
ELBOW
TEE
GATE VALVE
(FULLY OPEN)
CHECK VALVE
GLOBE VALVE
BUTTERFLY VALVE
PUMP
3xD
2xD
MINIMUM STRAIGHT PIPE
MINIMUM STRAIGHT PIPE
7xD
MINIMUM STRAIGHT PIPE
STANDARD CONCENTRIC
REDUCERS
(NO DISTANCE REQUIRED)
ELBOW
TEE
ANY VALVE
MINIMUM PIPING REQUIREMENT
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.
Page 10
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Installation & Operation
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.
If a meter must be installed downstream of a chemical injection connection, 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/chemical solution to reach the meter in a complete, homogeneous mixture. 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.
Sometimes, due to circumstances, it’s difficult to specify the exact downstream placement distances. Contact
Badger Meter Technical Support to review your application, if necessary.
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Page 11
Model M-5000 Mag Meter
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, gravity flow applications, etc.
To eliminate these situations, do not install the meter at the highest point of the pipeline.
WRONG
RIGHT
FLOW
FLOW
FLOW
FLOW
RIGHT
WRONG
FLOW
FLOW
WRONG
RIGHT
Do 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.
RIGHT
WRONG
RIGHT
WRONG
FLOW
RIGHT
FLOW
FLOW
FLOW
FLOW
FLOW
WRONG
Do not install in a vertical, downward position.
Position "On/Off" 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.
Page 12
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Installation & Operation
Meter Gaskets and Grounding
Gasket and grounding requirements must be considered when determining the meter location, orientation and
application.
Meter/Pipeline Connection Gaskets
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.
GASKETS RECOMMENDED
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.
If using a grounding ring in the detector/pipeline connection, place the ring between two gaskets. (See NonConductive Pipe Grounding on page 14.)
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Page 13
Model M-5000 Mag Meter
Meter Grounding
Process pipeline material can be either electrically conductive (metal) or not electrically conductive (made of or
lined 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 drilling and tapping the
flanges and install a grounding screw (not provided).
These grounding straps must be copper wire, at least 12AWG 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: If the 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, install
a pair of grounding rings between the mating flanges at both ends of the meter. See the following illustration.
GROUNDING RING
GROUNDING RING
GASKETS RECOMMENDED
In this case, the grounding straps should be connected to both of the grounding rings and to a good, solid earth
ground. Grounding rings are available in stainless steel. If the fluid is too aggressive for stainless steel, order a
meter with the optional grounding electrode in a material compatible with the fluid.
Amplifier Mounting Configuration Options
There are two configuration options for mounting the amplifier. There are many options to accommodate 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 minimizes installation wiring.
Page 14
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Installation & Operation
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 installing the meter in a vault, order the remote amplifier option. Do not install the amplifier inside a vault. We
also recommend ordering the remote meter package with the submersible option (NEMA 6P). This will eliminate
any potential problems resulting from humidity or temporary flooding in the vault.
Note: The National Electronics Manufacturer's Association (NEMA) 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:
•
Keep all lines as short as possible.
•
Use twisted pair shielded wire for all output wiring.
• Observe all applicable, local electrical codes.
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Page 15
Model M-5000 Mag Meter
Opening the M-5000 Cover
The M-5000 amplifier's design allows opening 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.
Page 16
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Installation & Operation
Power
Battery
(2) D-cells battery pack (1/2" to 6") or Double (2) D-cell battery pack (8" to 24").
Battery Life
Standard Pack
Sampling
Expected Life
0.25
4
8
15
3 months
4 years
8 years
10 years
These calculations are for a standard battery pack, with two D-size batteries., with communication and outputs
OFF, at a temperature of 25º C (77º F).
Battery Replacement
1) Save totalizers in the M-5000 menu (MainMenu>Misc>Battery>Change>).
2) Remove the circuit board, battery cover and the old battery pack.
3) Put the new battery pack into the enclosure, connect the new battery pack to M-5000 PCB
and fasten PCB with four M3,5 screws with serrated lock washer.
4) Replace the battery cover, circuit board and enclosure cover.
5) Set time and date in the M-5000 menu (MainMenu>Misc>Date DMY>)
(MainMenu>Misc>Time>).
6) Set burned capacity of battery pack through Modbus to 0.0Ah.
7) Set initial capacity of battery pack through Modbus to 38.0Ah (38.0Ah for standard battery
pack).
Note: Totalizers and configuration remain unaffected battery replacement.
Battery
Amplifier Housing Components - Exploded View
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Page 17
Model M-5000 Mag Meter
Intentional Blank Page
Page 18
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Installation & Operation
Remote Mount Installation
If installing the M-5000 amplifier in a remote location, review the procedures in this section.
Mount Bracket to Amplifier
1. Align bracket-mounting holes with amplifier mounting holes.
2. Attach bracket to amplifier with supplied screws. Torque screws to 80 in. lb.
Wiring Configuration
Wiring between the detector and the M-5000 amplifier comes complete from the factory. If installation requires
the use of conduit, Badger Meter recommends following these steps when wiring the detector to the amplifier.
1. Remove the junction box lid. Carefully remove the wires connected to the terminal blocks
that run to the M-5000 amplifier. See the chart below for a reference of wire color to terminal connection.
2. Run cable through the conduit from the amplifier location while retaining the wiring of the
cable to the amplifier, as supplied.
3. Complete conduit assembly on both ends and rewire the cable into the junction box as it
was previously wired.
Wiring for Remote Configuration
Remote style M-5000 amplifier models can be ordered with standard cables measuring 15, 30, 50 and 100 feet.
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Page 19
Model M-5000 Mag Meter
Junction Box
Connection No.
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.
Page 20
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Installation & Operation
Configuring Output
This section describes wiring the following M-5000 outputs:
• Digital outputs
• Communication
When the sensor and the amplifier have been wired, wire any outputs to the M-5000 amplifier.
Follow all of the safety precautions and local code to prevent electrical shock and damage to the electronic
components.
Circuit Board Diagram
Not Used
RX
RS232
TX
COM
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Outputs
Description
Output 1
Passive max. 30 VDC, 20 mA
Max. Frequency 100 Hz
Output 2
Passive max. 30 VDC, 20 mA
Max. Frequency 100 Hz
Output 3
Passive Max 30 VDC, 20 mA
Output 4
Passive Max 30 VDC, 20 mA
RS232
Modbus RTU
+
_
Output 1
+
_
Output 2
+
_
Output 3
+
_
Output 4
Page 21
Model M-5000 Mag Meter
Digital Output Wiring Diagrams
Positive Pulse Logic
Negative Pulse Logic
Digital Output Wiring Diagram
Digital Output Selections:
Output 1
Output 2
Output 3
Output 4
Forward Flow Pulse
Output
Reverse Flow Pulse Output
Flow direction (Forward
vs. Reverse)
High/Low flow alarm (0 –
100% of full scale, resolution 1%)
High/Low flow alarm (0 –
100% of full scale, resolution 1%)
High/Low flow alarm (0 –
100% of full scale, resolution 1%)
High/Low flow alarm (0 –
100% of full scale, resolution 1%)
Empty pipe alarm
Empty pipe alarm
Empty pipe alarm
Empty pipe alarm
Error alarm
Error alarm
Error alarm
Error alarm
Can be used with AMR
when pulse width is set to
50 milliseconds s
Outputs are configurable for Pulses/Unit (PPU) and Pulse Width (PW). The PW is configurable from 5 – 500
milliseconds, with a frequency limit is 100Hz. The PPU is displayed using an automatically selected resolution.
The high/low flow alarm functionality is configurable for maximum and minimum set points as a percentage of
full-scale flow. Configurable value are settable from 0 – 100% in 1% increments.
Page 22
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Installation & Operation
Programming the M-5000
The M-5000 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 M-5000 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 combination of these three buttons.
The up-arrow button allows scrolling through eight menu screens. This button is also used to advance numerical digits to change values, such as frequency, period, EP level, etcetera, 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 displays meter and register condition icons and current screen descriptions.
The icons, from left to right indicate:
battery status (shown full charge), data communication, password-protected amplifier lock (shown unlocked),
warning/caution condition and empty pipe detection
Battery Levels
The battery icon indicates three levels of capacity:
Greater than 3 volts (maximum = 3.6V)
Greater than 2 volts, less than 3 volts (recommended battery replacement)
Less than 2 volts (measuring has stopped)
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Page 23
Model M-5000 Mag Meter
Display Menu Screen Hierarchy Structure
T 1+
T1T1n
T2+
T2T2n
Errors
Login
Main Menu
Meter Setup
Diameter
Capacity
Detector Zero
Language
Amplifier Factor
Date DMY
Coil Current
Time
Frequency
EEPROM
Period
Battery
Empty Pipe Level
Factory CFG
Empty Pipe On Off
Restart
Info
Flow Unit
Full Scale Flow
Serial Number
Version
Totalizer Unit
Outputs
Voltage
Detector Factor
Empty Pipe Measure
Measure
Misc
Compilation Date
PINs
Pins Control
Low Flow Cutoff
User
Direction
Service
T1 Reset
Admin
Pulse/Unit
Pulse Width
Set Min
Set Max
Simulation
Out1Oper
Out2Oper
Out3Oper
Out4Oper
Out1Mode
Out2Mode
Out3Mode
Out4Mode
Communication
Interface
BaudRate
Parity
Address
Page 24
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Installation & Operation
Security
The M-5000 security feature allows the option to restrict access to the meter by way of a five-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 M-5000 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: For a lost 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 M-5000 user will have access to all functions.
Note: The security settings will also apply to remote access. All remote via modbus writes to the meter will be
blocked unless the user is remotely logged in.
Setting a PIN
1. From the Main Menu, press the right-arrow button.
2. From the Meter Setup menu, press the up-arrow button until the Pin menu is displayed.
3. Press the right-arrow button to display the PINS Control menu.
4. Press the right-arrow button to flash ON or OFF.
5. With either ON or OFF flashing, press the up-arrow button to display ON.
6. Press the EXIT SAVE button to save the ON setting.
7. With the Control menu flashing, press the up-arrow button to display the desired security level (user
service, admin, etc.).
8. With the desired security level flashing, press the right-arrow button to display the upper row of six
zeros (digits).
9. Press the 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 Login to the amplifier.
Note: Be sure to log off when you have completed work with the M-5000. Otherwise, a five-minute time delay
occurs between the most recent activity and the time when the M-5000 automatically logs off.
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Page 25
Model M-5000 Mag Meter
Intentional Blank Page
Page 26
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Installation & Operation
M-5000 Main Menu Programming Options
The following M-5000 programming options are available from the Main Menu:
•
•
•
•
•
•
•
Meter Setup
Measure
Outputs
Communication
Miscellaneous
Information
Pin
Note: Options that are listed [Factory Set] should not be changed without specific directions from authorized
Badger Meter personnel.
The applicable security level for each menu option is indicated as follows:
A S U Administrative
Service
Note: Parameters indicated by the battery icon, if changed will affect battery performance
User
The factory default values are shown, enclosed in brackets.
Meter Setup
Empty Pipe ON/OFF
[ON]
When set to ON, an Empty Pipe condition indicates to the outputs and the display
that the meter is not completely filled. When set to Off, empty pipe conditions are
not detected..
S
Power Line Frequency This parameter provides measuring immunity to industrial noise from a power supply feed.
[60 Hz]
Factory-set.
S
Diameter
[Factory Set]
This parameter is set at the factory. In the event the amplifier is replaced, verify that
the pipe diameter matches the installed pipe size.
A
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Page 27
Model M-5000 Mag Meter
Meter Setup
Period
This parameter configures the frequency (0 seconds to 63 seconds) of sampled measurements.
[15 Seconds]
A
Note: Parameters indicated by the battery icon, if
changed will affect battery
performance.
Detector Factor
[Factory Set]
A
This parameter is set at the factory. This factor compensates for accuracy error as a
result of the installed detector.
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.
[Factory Set]
This parameter compensates for accuracy error as a result of the installed detector.
A
Amplifier Factor
[Factory Set]
In the event the amplifier is replaced, this parameter must be reprogrammed with
the original detector factor.
This parameter is set at the factory. This factor compensates for accuracy error as a
result of the installed amplifier.
Read Only
Coil Current
[Factory Set]
This parameter is set at the factory. This factor compensates for accuracy error as a
result of the installed amplifier.
Read Only
Page 28
(12-10)
Installation & Operation
Measure
Flow Unit
[GAL/Min]
U
Totalizer Unit
[GAL]
U
(12-10)
This parameter lets you set the unit of measure for the flow rate and full scale flow.
Changing this parameter readjusts the full scale flow parameter. For example, changing
from GPM to GPS would change the full scale flow from 60 GPM to 1 GPS.
Display
Flow Unit
Display
Flow Unit
L/S
Liter/Second
GAL / Min
Gallons/Min.
L / Min
Liter/Minute
GAL / h
Gallons/Hour
L/h
Liter/Hour
MG / D
MegaGallon/Day
M3 / S
Cubic Meter/Sec.
IG / S
ImperialGallon/Sec.
M3 / Min
Cubic Meter/Min.
IG / Min
ImperialGallon/Min.
M3 / h
Cubic Meter/Hour
IG / h
ImperialGallon/Hour
Ft3 / S
Cubic Feet/Sec.
OZ / Min
Ounce/Min
Ft3 / M
Cubic Feet/Min.
bbl / Min
Barrel/Min
Ft3 / h
Cubic Feet/Hour.
GAL / S
Gallons/Sec.
This parameter establishes the units of measure for the totalizers.
Display
Totalizer Unit
L
Liters
hL
Hectoliter
M3
Cubic Meters
Ft3
Cubic Feet
GAL
U.S. Gallons
MG
MegaGallons
IG
Imperial Gallons
BBL
Barrel
OZ
Fluid Ounces
AFt
Acre per foot
Page 29
Model M-5000 Mag Meter
Measure
Full Scale Flow
[Factory Set]
S
This parameter sets the maximum flow the system is expected to measure. This parameter has influence on other system parameters. These parameters include:
• 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 set
point 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: 0.328 to 32.8 FPS (0.1 to 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 25%,
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.
Low Flow Cutoff
[2%]
Low flow cutoff defines the threshold at which flow measurement will be forced to zero.
The cutoff value can be set from 0% to 10% of the full scale flow. Increasing this threshold will help prevent false readings during “no flow” conditions possibly caused by pipe
vibration or inherent system noise..
U
Page 30
(12-10)
Installation & Operation
Measure
Direction
[Bi-Directional]
S
This parameter allows setting the meter to measure forward flow only (uni-directional)
or both forward and reverse flow (bi-directional).
Uni-Directional
Flow is totalized in only one direction. The flow direction is indicated by the arrow
printed on the detector label. Uni-directional measurements on the main display screen
include:
T1: Registers forward flow, resettable by menu or Modbus RTU.
T2: Registers forward flow, non-resettable.
Bi-Directional
Flow is totalized in both directions. Bi-directional 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
Ths parameter allows the reset of totalizer 1.
[N/A]
S
(12-10)
Page 31
Model M-5000 Mag Meter
Outputs
Digital Output
Pulse/Unit
[1]
S
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 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 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
[0 ms]
S
This parameter establishes the ON duration of the transmitted pulse.
The configurable range is from 0 to 500ms.
• 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 50% 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.
Page 32
(12-10)
Installation & Operation
Outputs
Digital Output
Set Min.
[0%]
This parameter establishes, as a percentage of full scale flow, the
threshold at which the output alarm will be activated. Flow rates
below the threshold will activate the output alarm.
S
Set Max.
[100%]
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.
S
Output Mode
[1: Normally
Open]
[2: Normally
Open]
[3: Normally
Open]
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.
[4: Normally
Open]
S
(12-10)
Page 33
Model M-5000 Mag Meter
Outputs
Digital Output
Operation
This parameter provides configuration of the functional operation of the associated
output. The following operations are supported:
[1: OFF]
• Forward Pulse – Generates pulses during forward flow conditions (output 1 - only)
[2: OFF]
• Reverse Pulse – Generates pulses during reverse flow conditions (output 2 - only)
[3: OFF]
• Flow Direction – Provides indication on current flow direction (output 3 - only):
OUTPUT TYPE
[4: OFF]
FLOW DIRECTION
S
NORMALLY OPEN
NORMALLY CLOSED
REVERSE
Closed
Open
FORWARD
Open
Closed
NO FLOW
No Change
No Change
• Flow Set Point – Provides indication when flow rate exceeds thresholds defined by
flow set points (outputs 1, 2, 3, 4)
• Error Alarm – Provides indication when meter has error condition. Error conditions
include, empty pipe error, full scale flow error, and detector error (outputs 1, 2, 3, 4)
• Empty Pipe Alarm – Provides indication when pipe is empty (outputs 1, 2, 3, 4)
Simulation
[OFF]
S
Page 34
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% to
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).
(12-10)
Installation & Operation
Communication: Port Settings
Interface
[OFF]
S
This parameter provides communication port configuration.
• Serial (Modbus RTU)
• Irda (Modbus RTU)
Baud Rate
This parameter sets the baud rate.
[9600]
The following baud rates are supported:
S
• 9600
• 1200
• 2400
Parity
This parameter sets the parity.
[Even]
The following parities are supported:
S
• Even
• Odd
• Mark
Address
This parameter configures the Modbus address in the range from 1 to 247.
[01]
S
(12-10)
Page 35
Model M-5000 Mag Meter
Misc
Voltage
Displays the current battery voltage.
[Read Only]
Capacity
Displays the current battery capacity (0/38V to 38/38V).
[Read Only]
Note: A new battery should be at or near a 0/38 reading.
Language Select
This parameter allows changing the current language. The M-5000 supports alternate
languages along with English as the default setting.
[English]
U
The following languages are supported:
German (Deutch), Czech (Cestina), Spanish (Espanol), French (Francai), Russian (PycckhIIII)
.
Date, Month, Year
[N/A]
A real-time clock. The month, date and year must be reprogrammed after the battery is
replaced.
S
Time
[N/A]
A real-time clock. The month, date and year must be reprogrammed after the battery is
replaced.
S
EEPROM
[N/A]
Format the EEPROM to erase all log files. Totalizers and configuration remain unaffected
during a format.
A
Battery
Saves Totalizers to non-volitile memory in preparation for battery replacement.
[N/A]
S
Restart
Provides the ability to reset the meter electronics.
[N/A]
S
Page 36
(12-10)
Installation & Operation
PIN
Security
[OFF]
A
User
Two options are available:
• ON (requires PIN configuration)
• OFF
Users logged in with this PIN will have access to all user-level. Users at this level do not
have access to Service or Admin functions.
U
Service
Users logged in with this PIN will have access to both service and user-level procedures.
User at this level will not have access to administrative functions.
S
Admin
Users logged in with this PIN will have access to all procedures. User at this level will
have full access to the meter.
A
(12-10)
Page 37
Model M-5000 Mag Meter
Maintenance
Mandatory, routine or scheduled maintenance should not be required for the Badger M-5000 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
These maintenance procedures are discussed in this section.
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 38
(12-10)
Installation & Operation
Troubleshooting
The M-5000 mag meter is designed for many years of optimal performance. However, should it malfunction,
there are certain things that we recommend you check before contacting our Technical Support department or
your local Badger Meter Representative.
Note: If the 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:
(12-10)
Description
Possible Cause
Recommended Action
Flow is present but display
is "0"
Disconnected signal cable.
Detector mounted opposite of the main
Flow direction (see arrow on the nameplate).
Coil or electrode cables exchanged.
Improper low flow cutoff or full scale flow.
Check signal cable.
Turn detector 180° or switch terminal E1 and E2 or
reprogram to bi-directional mode
Check cable connections for cross wiring.
Replace configuration defaults.
Inaccurate measuring
Improper calibration.
Wrong calibration parameter.
Pipe not fully filled, or air in pipe.
Invalid fluid conductivity.
Invalid fluid mixture.
Check the parameters (detector factor and size)
according to supplied data sheet.
Check if meter is completely filled with fluid.
Purge line to eliminate air bubbles.
Blank display
Dead battery
Replace battery.
Flow rate value known to
be wrong
Detector factor.
Deposits on electrodes and/or liner.
Incorrect pipe size programmed.
Check value on label.
Check and remove deposits.
Check size if necessary.
Flow rate indication unstable
Cable issue.
Grounding issue.
Partially full pipe.
Air in pipe.
Invalid fluid conductivity.
Make sure cable is shielded and not vibrating.
Make sure meter is properly grounded to a good
earth ground.
Make sure pipe is full of fluid.
Make sure fluid does not contain air bubbles.
Make sure amplifier is not too close to sources of
electrical interference.
Page 39
Model M-5000 Mag Meter
Errors & Warnings
•
•
PULSE_OVERLOAD_WARNING
Overflow occurred on the flow output
•
FLOW_OVERLOAD_WARNING
Flow exceeded the Full Scale of more than 25%.
•
LOW_POWER_WARNING
Battery voltage is smaller than 3.0V. Consider replacing the battery upon reading this warning.
•
EEPROM_ERROR
Configuration file is missing.
•
CONFIG_ERROR
Configuration file is corrupted.
•
Page 40
EMPTY_PIPE_WARNING
Measured impedance between the Empty Pipe electrode and the Ground exceeded the set value.
•
COMMON_MODE_VOLTAGE_OVERLOAD
Common mode voltage is smaller than -2.0V or larger than +4.1V.
•
MEASURE_TIMEOUT
Measurement was not completed in 250ms
PREAMPLIFIER_OVERLOAD
Input voltage exceeded the limits. Maximum polarization is ±227mV; maximum power line noise is 10.6mV; maximum useful signal is 10.7mV.
(12-10)
Installation & Operation
Dimensions in
inches (millimeters)
Detector Specifications
B
C
(O.D.)
A
Meter with M-5000 Amplifier
SPECIFICATIONS - Detector
Flow Range: 0.328 to 32.8 fps (0.1 to 10 m/s)
Sizes: 1/2-inch to 24 inches (15 mm to 600 mm)
Min. Conductivity: ≥ 20 micro siemens/cm
Accuracy:
± 0.50% of rate for velocities greater than 1.64 ft/s
(0.50 m/s)
± 0.008 ft/s (± 0.0025 m/s) for velocities less
than1.64 ft/s (0.50 m/s)
Electrode Materials: Standard: Alloy C
Optional: 316 stainless steel
Liner Material: PTFE 1/2 inch to 24 inches, hard
rubber 1 inch to 24 inches
NSF Listed: Models with hard rubber liner 4-inch
size and larger; PTFE liner (all sizes).
(12-10)
Meter with junction box for remote M-5000 Amplifier
Fluid Temperature:
With Remote Amplifier:
PTFE 311°F (155°C)
Hard Rubber 178°F, (80°C)
With Meter-Mounted Amplifier:
PTFE 212°F (100°C)
Hard Rubber 178°F, (80°C)
Pressure Limits:
Maximum allowable non-shock pressure and temperature
ratings for steel pipe flanges, according to American
National Standard ANSI B16.5. Examples: 150-pound
flanges, rated 285 PSI at ambient temperature; 300-pound
flange rated 740 PSI at ambient temperature.
Coil Power: Pulsed DC
Ambient Temperature: -4°F to 140°F (-20°C to 60°C)
Pipe Spool Material: 316 stainless steel
Meter Housing Material: Carbon steel welded
Flanges: Carbon steel - Standard (ANSI B16.5 Class 150 RF)
316 stainless steel (optional)
Meter Enclosure Classification: NEMA 4X (IP66)
Optional: Submersible NEMA 6P (remote amplifier
required)
Junction Box Enclosure Protection:
(for remote amplifier option) Powder-coated die-cast
aluminum, NEMA 4 (IP65)
Cable Entries: 1/2-inch NPT Cord Grip
Optional Stainless Steel Grounding Rings:
Meter Size
Thickness (of one ring)
Up through 10 inches
.135 inch
12 to 24 inches
.187 inch
Page 41
Model M-5000 Mag Meter
Amplifier Specifications
Power Supply
Internal lithium batteries 3.6 volt
Battery Life
10 years
Empty Pipe Detection
Field-tunable for optimum performance based on
specific application
± 0.50% of rate for velocities greater than 1.64 ft/s
Pulse Width
Programmable 5 to 500ms
(0.50 m/s)
Min-Max Flow Alarm
Programmable outputs 0 to 100% of flow
± 0.008 ft/s (± 0.0025 m/s) for velocities less than
Units of Measure
Accuracy
1.64 ft/s (0.50 m/s)
Gallons, ounces, MGD, liters, cubic meters, cubic feet,
imperial gallon, barrel, hectoliter, acre feet
Galvanic Separation
Functional 50 volts
Low Flow Cut-Off
Programmable 0 to 10% of maximum flow
Liquid Crystal Display
Two lines x 15 characters (7-top + 8-bottom)
Programming
Three external buttons
Sampling Rate
Programmable from 1 to 63 seconds
Repeatability
±0.1%
Flow Range
0.328 to 32.8 ft/s (.03 to 10ms)
Minimum Fluid
Conductivity
≥ 20 micro siemens/cm
Processing
Low power microcontroller (16 bit)
Flow Direction
Uni-directional or bi-directional. Two separate programmable totalizers for uni-directional measurement.
Mounting
Detector-mount or remote wall mount (bracket supplied)
Outputs (4 digital)
Galvonically isolated open collector, 30 VDC maximum,
20mA each, maximum output frequency at 100 Hz
Cable Connection
Four 1/2-inch NPT Cord Grip
Ambient Temperature
-4º F to 140º F (-20º C to 60º C)
Serial Communication
RS232 Modbus RTU, IRDA
Outputs
Page 42
High/low flow alarm (0-100% of flow), error alarm,
Housing
NEMA 4X (IP66), cast aluminum, powder-coated
paint
empty pipe alarm, flow direction
(12-10)
Installation & Operation
Intentional Blank Page
(12-10)
Page 43
M-Series® is a registered trademarks of Badger Meter, Inc.
Copyright 2010 Badger Meter, Inc. All rights reserved.
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.
Badger Meter | P.O. Box 245036, Milwaukee, Wisconsin 53224-9536
800-876-3837 | infocentral@badgermeter.com | www.badgermeter.com
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